souvenir - IIT Guwahati

Transcription

5th International & 26th All India
Manufacturing Technology,
Design and Research
Conference
AIMTDR 2014
December 12
12−
−14, 2014
SOUVENIR
Editors
Dr. Uday S. Dixit
Dr. R
R. Ganesh Narayanan
Dr. M. Ravi Sankar
Souvenir of 5th International & 26th All India Manufacturing Technology, Design
and Research Conference (AIMTDR 2014), December 12-14, 2014, IIT Guwahati
Editors: Dr. U.S. Dixit, Dr. R. Ganesh Narayanan and Dr. M. Ravi Sankar
Front cover designed by Dr. S. N. Joshi, Assistant Professor, Department of
Mechanical Engineering, IIT Guwahati
The opinions expressed by the authors are their own and editors cannot accept any legal responsibility
or liability for the views of authors, any omission or inadvertent errors.
 Organizing Secretary, AIMTDR 2014
ISBN: 978-8-19274-610-4
Printed at DNS Publisher & Distributors, Guwahati
CONFERENCE ORGANIZING COMMITTEE
Patrons: Dr. Gautam Biswas, Director, IIT Guwahati and Dr. Gautam Barua, Ex-Director, IIT
Guwahati
Chairmen: Dr. Anoop K. Dass, Head, Department of Mechanical Engineering, IIT Guwahati and
Dr. Pinakeswar Mahanta, Dean of Faculty Affairs, IIT Guwahati
Organizing Secretary: Dr. Uday S. Dixit, Professor, Department of Mechanical Engineering, IIT
Guwahati
Joint Organizing Secretaries: Dr. R. Ganesh Narayanan and Dr. M. Ravi Sankar, Assistant Professors,
Department of Mechanical Engineering, IIT Guwahati
Treasurer: Dr. Deepak Sharma, Assistant Professor, Department of Mechanical Engineering, IIT
Guwahati
Members
Dr. P.S. Robi, IIT Guwahati
Dr. D.K. Sarma, NIT Meghalaya
Dr. A.K. Das, IIT Guwahati
Dr. Pankaj Biswas, IIT Guwahati
Dr. Vinayak Kulkarni, IIT Guwahati
Dr. Atanu Banerjee, IIT Guwahati
Dr. S.N. Joshi, IIT Guwahati
Dr. Sachin D. Kore, IIT Guwahati
Dr. Debkumar Chakrabarti, IIT Guwahati
Dr. Anoop Gogoi, IIT Guwahati
Dr. Swarup Bag, IIT Guwahati
Dr. Dipankar Narayan Basu, IIT Guwahati
Dr. Karuna Kalita, IIT Guwahati
Dr. S.K. Dwivedy, IIT Guwahati
Dr. Arbind K. Singh, IIT Guwahati
Dr. Manas Das, IIT Guwahati
Mr. S.M. Mahajan, Ex-ED, BHEL, Haridwar
Mr. Munish Narain, IWS Northen Zone
Ms. Chaitali Brahma, Registrar, CIT Kokrajhar
NATIONAL ADVISORY COMMITTEE (NAC)
President: Shri Pranip K. Borthakur, Director (Offshore), ONGC
Vice-President: Prof. A.K. Chattopadhyay, IIT Kharagpur, India
Members
Prof. Amitabha Ghosh, IIT Kanpur, Kanpur
Prof. V. K. Jain, IIT Kanpur
Prof. B.B. Ahuja, Government College of Engineering, Pune
Prof. Bijoy Bhattacharyya, Jadavpur University, Kolkata
Prof. S.G. Deshmukh, IIIT & M, Gwalior
Shri. N.K. Dhand, MD, ACE Micromatic, Bangalore
Prof. U.S. Dixit, IIT Guwahati, Guwahati
Prof. P.K. Jain, IIT Roorkee, Roorkee
Shri. M. Lakshminarayan, MD, Harman International, Bangalore
Prof. G.K. Lal, IIT Kanpur, Kanpur
Prof. N.K. Mehta, IIT Roorkee, Roorkee
Prof. P.V. Mohanram, PSG College of Technology, Coimbatore
Dr. T. Mukherjee, TATA Steel Ltd., Jamshedpur
Shri. P. Muralidharan, LUCAS-TVS Ltd., Chennai
Prof. S. Narayanan, VIT University, Vellore
Prof. S.S. Pande, IIT Bombay, Mumbai
Dr. D.R. Prasadaraju, Advisor, DST, New Delhi
Prof. P. Radhakrishnan, PSG Institute of Advanced Studies, Coimbatore.
Prof. V. Radhakrishnan, IISST, Trivandrum
Prof. N. Ramaswamy, Chennai
Shri. C.P. Rangachar, Yuken India Ltd., Bangalore
Dr. B.R. Satyan, CMTI, Bangalore
Prof. T. Selvaraj, NIT Trichy, Tiruchirappalli
Prof. H.S. Shan, Chandigarh
Prof. M.S. Shunmugam, IIT Madras, Chennai
Shri. S.G. Shirgurkar, ACE Designers Ltd., Bangalore
Dr. V. Sumantran, Hinduja Automotive, India
Dr. V.K. Suri, BARC, Mumbai
Shri. P. Venu Gopalan, DRDL, Kanchanbagh, Hyderabad
Prof. Vinod Yadava, Motilal Nehru Nat. Inst. of Tech., Allahabad
Prof. B. Satyanarayan, A.U., Visakhapatnam
Shri P. Mohanram, IMTMA, Bangalore
Prof. N. Ramesh Babu, IIT Madras
Prof. P.V. Rao, IIT Delhi
Prof. Jose Mathew, National Institute of Technology Calicut
Scientific Advisory Committee
Prof. Ajay P. Malshe, University of Arkansas, USA
Prof. Hong Hocheng, National Tsing Hua University, Taiwan
Prof. Mustafizur Rahman, NUS, Singapore
Prof. S. Chandrasekhar, Purdue University, USA
Prof. Tae Jo Ko, Yeungnam University, S. Korea
Prof. Y.S. Liao, National Taiwan University, Taiwan
Prof. Kamlakar. P. Rajurkar, University of Nebraska, USA
Prof. B.J. Davies, Editor, Int. Journal of AMT, UK
Prof. Andrew Y. C. Nee, NUS, Singapore
Prof. Shiv Gopal Kapoor, University of lllinois, USA
Prof. J. A. McGeough, University of Edinburgh, UK
Prof. Kornel Ehmann, Northwestern University, USA
Prof. John Sutherland, Purdue University, USA
Prof. Philip Koshy, McMaster University, Canada
Prof. T. A. Dean, University of Birmingham, UK
Prof. Abhijit Chandra, Iowa State University, USA
Prof. Tugrul Ozel, University of New Jersey, USA
Prof. J. Paulo Davim, University of Aveiro, Portugal
Prof. Rakesh Nagi, University of Buffalo, USA
Prof. Alok K. Verma, Old Dominion University, Virginia, USA
Sub Committees
Publication and Printing
Dr. S.N. Joshi, Dr. Ganesh Narayanan, Mr. Bishnu Tamuli, Mr. Mrinal Chakraborty
Sponsorship
Prof. P.S. Robi, Dr. D.K. Sarma, Prof. Pradeep Yammiyavar, Prof. A.K. Gogoi, Dr. S. Bag
Accommodation and hospitality
Dr. Pankaj Biswas, Mr. Kaustubh Acharyya, Dr. Manas Das, Dr. S.D. Kore, Mr. Rituraj Saikia, Mr.
N.K. Das, Dr. Chandan Mahanta
Transportation
Dr. S. Bag, Dr. Karna Kalita, Dr. M. Ravi Sankar, Mr. Mrinal Sarma, Mr. Dilip Chetry, Mr. Sanjib
Sarma, Mr. Kuntil Bhuyan, Mr. Rituparana Sarma,
Publicity
Mr. Labnu K. Konwar, Prof. S.K. Kakoty, Mr. Sanjib Kumar Saikia, Mr. Amarendra Goswami
Cultural activities
Dr. Sidananda Sarma, Mr. Minesh Chandra Medhi, Mr. Bijoy Kumar Choudhuri
Catering
Dr. S.N. Joshi, Dr. S.D. Kore, Dr. Debakumar Chakraborti, Mr. Pranjol Paul, Mr. Dilip Chetry
Reception and Registration
Dr. Deepak Sharma, Dr. S.N. Joshi, Dr. Manas Das, Mr. Chandan Banikya, Mr. Nandeswar Das, Dr.
A.N. Reddy
Program Schedule and Sessions
Dr. S. Senthilvelan, Dr. Ganesh Narayanan, Dr M Ravi Sankar, Dr. S. Kanagaraj, Dr. Vinayak
Kulkarni, Dr. Sachin Singh Gautam, Dr. Atanu Banerjee, Prof. Santosha Kumar Dwivedy, Dr.
Sukhomay Pal, Dr Dipankar Narayan Basu.
OUR ASSOCIATES
NIT Meghalaya
Indian Welding Society, Guwahati Chapter
CIT Kokrajhar
WizIQ
We gratefully acknowledge the funding
received from………..
(1) Department of Science and Technology (DST), New
Delhi
(2) Department of Atomic Energy (DAE), Board of
Research in Nuclear Sciences (BRNS)
(3) Oil and Natural Gas Corporation (ONGC) Limited
Private Sector Sponsors of AIMTDR 2014
Emami Limited
Zwick Roell Testing Machines Pvt. Ltd.
Ametek Instruments India Pvt. Ltd.
Nanovision Scientific Applications Pvt. Ltd.
Maverick Technologies, Guwahati
Organizing team gets moral support from…..
Dr. R.P. Singh, Chairman, Board of Governors, IIT Guwahati
Prof. Gautam Barua
Former Director, IIT Guwahati
Shri Pranip K. Borthakur, President, NAC
Prof. Gautam Biswas, Director, IIT Guwahati
Prof. A.K. Chattopadhyay,
Vice-President, NAC
Indian Institute of Technology Guwahati
Message from the Chairman, Board of Governors
Dr. R.P. Singh
I am pleased to know that Mechanical Engineering Department of Indian Institute of Technology Guwahati is
organizing 5th International and 26th All India Manufacturing Technology, Design and Research (AIMTDR)
conference during 12−14 December 2014. AIMTDR conference series has a long history. The first AIMTDR
conference was started in 1967 at Jadavpur University, Kolkata. The 1st International and 22nd National
AIMTDR was held at IIT Roorkee. After every two years, AIMTDR is held in one of the premier institutions
of India. This year IIT Guwahati got an opportunity to hold it first time in North East India.
India has the potential to become an economic superpower by focussing on the manufacturing sector. Our
Prime Minister has righly given the slogan “Make in India”. In order to fulfil the dream of India becoming an
excellent destination for manufacturing sector, there is a need to develop infrastucture and manpower.
Manpower growth need to be inclusive staring from the level of technician to reseracher. It is also necessary
that academic institutions should play a major role in training the manpower as well as carrying out the
innovations in the field of manufacturing. The scintific principles should be exploited to attain quality and
productivity. In that context, the conference theme “ENHANCING MANUFACTURING THROUGH
NEWER SCIENTIFIC CONCEPTS” is very pertinent.
The conference has received huge response from the delegates. Afterr rigorous reviwing, the organizers have
selected more than 400 contributed papers. In addition, more than 20 natioanl and international researchers will
address the delegates. It is heartening to note that there are a number of young participants in the conference.
Another notable feature is the participation of industry in the conference.
I am pleased to note that IIT Guwahati is helping the neigbouring institutes by associating them in various
academic/resaerch activities. NIT Meghalaya and Central Institute of Technology Kokrajhar are associated in
the organization of thio conference. Guwahati chapter of Indian Welding Society is also involved in managing
the technical sessions related to welding.
I welcome all the guests, invited speakers, authors of papers and delegates. I hope that everyone will have a
comfortable stay in the serene and scenic campus of IIT Guwahai. I offer my best wishes and appreciation for
the organizing team.
(Dr. R.P. Singh)
Message from the President of National Advisory Committee
I am pleased to note that the prestigious All India Manufacturing Technology, Design and
Research (AIMTDR) conference is being held at Indian Institute of Technology Guwahati
during 12−14 December 2014.
The AIMTDR conferences focus on the broad field of
manufacturing .It is a biennial event. It was elevated to the status of an international event in
2006 at IIT Roorkee. It is the first time that this conference is being organized in North East
region. The main theme of the conference is ENHANCING MANUFACTURING THROUGH
NEWER SCIENTIFIC CONCEPTS. The conference will send a message that the excellence in
manufacturing can be achieved only by applying scientific principles and techniques to it.
As the President of National Advisory Committee, I am delighted at the huge response from
industry and academia. About 800 contributed papers were received initially, which were
subjected to rigorous review process. Finally, more than 400 papers are planned for
presentation apart from more than twenty invited speakers. I am sure that the conference will
provide an excellent platform for interaction of industry and academia. I wish the conference
all success.
(Pronip Kumar Borthakur)
Message from Vice-President of National Advisory Committee
Professor Ajay Kumar Chattopadhyay
Professor, Department of Mechanical Engineering
Indian Institute of Technology Kharagpur
Kharagpur, India – 721302
AIMTDR has been playing a very important role in bringing together professors, researchers and practicing
engineers to discuss issues concerning various facets of manufacturing. The theme of 26th AIMTDR is
“Enhancing Manufacturing through Newer Scientific Concept”. The manufacturing means a generalized
activity which technologically transforms raw material into a useful product. Thus, one can recognize
significance of such activity in overall growth of economy of a country and quality of life. Unfortunately
manufacturing did not receive much attention from scientific community in past. It was considered to be
primarily an art based on experience, personal skill and intuition rather than on scientific knowledge and logic.
However, the situation has also changed rather drastically. The demand for low cost, energy efficient,
environment friendly manufacturing technology giving even better precision not only on conventional
materials but also on advanced materials is growing very fast and need for more rapid technological innovation
is strongly felt by the industry. Such thing cannot be achieved by a set of thumb rules, empirical formulae or
time consuming trial and error and one has to explore the laws of science that governs the technology.
However, manufacturing technology is multidisciplinary in nature and knowledge of various branches of
science pure or applied is essential to understand the scientific principles, the backbone of the technology. It
may be mentioned that understanding the ‘know why’ behind the ‘know how’ must be translated into some
concrete means for further innovation in manufacturing technology and one has to demonstrate that not only in
the laboratory but also on the shop floor. It is hoped that contributing participants will present some of their
best research work, usefulness of which will be realized not only on manufacturing shop floor but also in class
room teaching and keep flag flying high for AIMTDR.
(A.K. Chattopadhyay)
Indian Institute of Technology Guwahati
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Guwahati-781039, India
Phone: +91-361-2582651
Fax: +91
+91-361-2582699 2690762
email: [email protected]
September 19, 2013
Message from Dean of Faculty Affairs
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Meassge from Head of Department of Mechanical Engineering
Professor Anoop K. Dass
Professor and Head
Department of Mechanical Engineering
IIT Guwahati
It is heartening to note that the 5th International and 26th All India Manufacturing, Design and Research
Conference is going to be held at IIT Guwahati from 12-14 December 2014. Such prestigious conferences not
only bring together researchers from within the country and abroad to exchange ideas for mutual enrichment,
but also contribute handsomely to building an intellectually vibrant atmosphere in the organizing institute.
I welcome all the participants to the conference and wish them all a satisfying experience.
(A.K. Dass)
Message from Director NIT Meghalaya
Professor Dilip K. Saikia
Director
National Institute of Technology Meghalaya
It is a privilege to be an Associate Organizing Institute of this Prestigious Conference AIMTDR-2014 being
held at IIT Guwahati. On behalf of National Institute of Technology Meghalaya I wish the Conference a Grand
Success.
(D.K. Sakia)
Editorial
All India Manufacturing Technology, Design and Research (AIMTDR) Conferences are organized once in
every two years at different places of India. This time, 26th National and 5th International AIMTDR conference
is being organized at Indian Institute of Technology Guwahati. NIT Meghalaya, NERIST Nirjuli and CIT
Kokrajhar have joined as our associates in organizing AIMTDR 2014. The conference received huge response
and approximately 800 abstracts were submitted. Abstracts were reviewed and based on the comments of
reviewers full papers were submitted. Each full paper was reviewed usually by two reviewers. The net result of
the process is that total 423 papers are being published in the proceedings of the conference.
The conference theme is ENHANCING MANUFACTURING THROUGH NEWER SCIENTIFIC
CONCEPTS. It is understood now that quality and productivity in manufacturing sector can be enhanced by
the application of scientific principles and techniques. More and more numbers of researchers are applying
computational and mathematical techniques to model the manufacturing processes. The conference has got a
large number of papers related to mathematical modeling. At the same time, the research in experimental field
is also getting strengthened.
The organizers have taken several measures to improve the effectiveness of AIMTDR conference. Due
publicity as well as discount in the registration fee was provided to attract young students to the conference.
This time, significant percentage of delegates comprises students. At the same time, there are invited speakers
and delegates from industry. However, there is less participation from abroad, although there are a number of
invited speakers. In future, AIMTDR has to strive hard for increasing the participation from abroad.
It is a matter of pleasure that Springer (India) has agreed to publish some books containing the selected papers
of conference. Two books viz. Laser Based Manufacturing and Advances in Material Forming and Joining
have already gone to press. Subtitles of both the books mention the name of AIMTDR. It is planned to bring
out a few more books and special issues of journals based on the papers presented in the conference. It is also
planned to keep the entire proceedings in the internet in the open access mode. We feel that these measures
will help in the dissemination of valuable information and in growing AIMTDR further.
A healthy tradition of AIMTDR is to identify two researchers—one from academia and other from
industry/R&D organizations—for conferring Life Time Achievment Award on them. Prof. V.K. Jain and Dr.
V.K. Suri are getting Life Time Achievements awards this year. We congratulate them and wish successful
active lives ahead for them.
A number of reviewers were engaged in the review task. We acknowledge their help. In particular the help
offered by Prof. P.K. Jain of IIT Roorkee, Dr. M. Chandrasekran of NERIST, Itanagar, Dr. D.K. Sarma of NIT
Meghalaya and faculty members of CIT Kokrajhar need special mention. We thank all the authors, invited
speakers, sponsors, members of national advisory committee and members of scientific advisory commitee.
We are very grateful to Prof. Gautam Biswas, Director, Prof. Gautam Barua, former director, Prof. Anoop K.
Dass, HOD Mechanical Engineering, and Prof. P. Mahanta, former HOD Mechanical Engineering for their
encouragment and providing necessary infrastructure. We also place on record the support provided by our
colleagues and students. Finally, we express our gratitude to Prof. Amitabha Ghosh who has kindly agreed to
grace the occasion as Chief Guest.
Uday S. Dixit, R. Ganesh Naryanan, M. Ravi Sankar ( [email protected], [email protected], [email protected] )
AIMTDR 2014, December 12-14, 2014
IIT Guwahati, Guwahati
Schedule of Invited Talks
SESSION 1: INVITED TALK
Prof. V.K. Jain (Hall 1)
Prof.Kornel F. Ehmann (Hall 2)
DAY 1: DECEMBER 12
Parallel session
11.00 – 11.30 AM
11.00 – 11.30 AM
Prof.AlokVerma (Hall 3)
Prof.BijoyBhattarcharya (Hall 4)
Parallel session
11.30 AM – 12.00 Noon
11.30 AM – 12.00 Noon
Mr. L.W. Khongwir (Hall 1)
Prof. S. K. Mukhopadhyay (Hall 2)
Parallel session
12.00 Noon – 12.30 PM
12.00 Noon – 12.30 PM
Prof. Hong Hocheng (Hall 3)
Dr.Sumitesh Das (Hall 4)
Parallel session
12.30 PM – 1.00 PM
12.30 PM – 1.00 PM
LUNCH
1.00 PM - 2.00 PM
Prof. Rajurkar (Hall 1)
Industrial talk by AMETEK (Hall 2)
Parallel session
2.00 PM – 2.30 PM
2.00 PM – 2.30 PM
Prof. S.K. Gupta (Via Skype)
Nanovision Scientific Applications
Parallel session
5.30 PM – 6.00 PM
Prof. N.K. Mehta (Hall 1)
Prof. Sanjay Kumar (Hall 2)
DAY 2: DECEMBER 13
Parallel session
9.00 AM – 9.30 AM
9.00 AM – 9.30 AM
Prof. V. Radhakrishnan (Hall 3)
Parallel session
9.30 AM – 10.00 AM
Prof. Shiv G. Kapoor (Hall 1)
Prof. M. S. Shunmugam (Hall 2)
Parallel session
10.00 AM – 10.30 AM
10.00 AM – 10.30 AM
Prof. Satish V. Kailas (Hall 3)
Prof. E. Raghu (Hall 4)
Parallel session
10.30 AM – 11.00 AM
10.30 AM – 11.00 AM
LUNCH
Prof. P.M. Pandey (Hall 1)
Dr. R. Balasubramaniam (Hall 2)
Dr. V.K. Suri (Hall 3)
Dr.Dipayan Sanyal (Hall 4)
Prof. Mustafizur Rahman (Hall 1)
Prof. Marc Madou (Hall 2)
1.00 PM – 2.00 PM
Parallel session
Parallel session
VALEDICTORY FUNCTION
2.30 PM – 3.00 PM
2.30 PM – 3.00 PM
DAY 3: DECEMBER 14
Parallel session
LUNCH
Dr. Ramesh Kumar (Hall 1)
Prof.Vinod Yadava (Hall 1)
Industrial talk by Taylor Hobson
2.00 PM – 2.30 PM
2.00 PM – 2.30 PM
9.00 AM – 9.30 AM
9.00 AM – 9.30 AM
1.00 PM – 2.00 PM
Parallel session
2.00 PM – 2.30 PM
2.00 PM – 2.30 PM
2.30 PM – 3.00 PM
3.30 PM – 4.30 PM
AIMTDR 2014, December 12-14, 2014
Schedule of Conference events
NOTE: Invited talks are named as Session 1, 2 …14, and Oral/Poster presentations are named as Session A, B ….F
DAY 1: DECEMBER 12
INAUGURATION: 9.00 AM - 10.30 AM
Welcome address by Organizing secretary and Chairman of the
conference
Felicitation of the guest
Lighting lamp
Release of conference souvenir and proceedings
Announcement of awards and felicitation of awardees
Address by Director
Address by Vice President, NAC
Address by President, NAC
Speech by Chief guest
Vote of thanks
9.10 – 9.20 AM
9.20 – 9.25 AM
9.25 – 9.30 AM
9.30 – 9.45 AM
9.45 – 9.55 AM
9.55 – 10.00 AM
10.00 – 10.10 AM
10.10 – 10.25 AM
10.25– 10.30 AM
TEA AND PHOTO SESSION
10. 30 – 11.00 AM
9.00 – 9.10 AM
Prof. V.K. Jain (Hall 1)
Prof.Kornel F. Ehmann (Hall 2)
Parallel session
11.00 – 11.30 AM
11.00 – 11.30 AM
Prof.Alok Verma (Hall 3)
Prof.Bijoy Bhattarcharya (Hall 4)
Parallel session
11.30 AM – 12.00 Noon
11.30 AM – 12.00 Noon
Mr. L.W. Khongwir (Hall 1)
Prof. S. K. Mukhopadhyay (Hall 2)
Parallel session
12.00 Noon – 12.30 PM
12.00 Noon – 12.30 PM
Prof. Hong Hocheng (Hall 3)
Dr.Sumitesh Das (Hall 4)
Parallel session
12.30 PM – 1.00 PM
12.30 PM – 1.00 PM
1.00 PM - 2.00 PM
LUNCH
Prof. Rajurkar (Hall 1)
Parallel session
2.00 PM – 2.30 PM
SESSION A: ORAL PRESENTATION: 2.30 PM–5.30 PM (10 mts. for each oral presentation; TOTAL: 18/session)
Session A1,
Session A2,
Session A3,
Session A4,
Session A5,
Session A6,
Machining
Metal Forming Joining/Welding
Advanced
Industrial
Miscellaneous
Manufacturing - I
Engineering&
Operations research
18 papers
18 papers
18 papers
18 papers
18 papers
18 papers
Prof. S.K. Gupta (Via Skype)
5.30 PM – 6.00 PM
SESSION B: POSTER PRESENTATION (Posters 1-59)
5.30 PM – 6.30 PM
CULTURAL PROGRAM
DINNER
6.30 PM – 8.00 PM
8.00 PM – 10.00 PM
DAY 2: DECEMBER 13
Prof. N.K. Mehta (Hall 1)
Prof. Sanjay Kumar (Hall 2)
Prof. V. Radhakrishnan (Hall 3)
Parallel session
9.00 AM – 9.30 AM
9.00 AM – 9.30 AM
Parallel session
9.30 AM – 10.00 AM
Prof. Shiv G. Kapoor (Hall 1)
Prof. M.S. Shunmugam (Hall 2)
Parallel session
10.00 AM – 10.30 AM
10.00 AM – 10.30 AM
Prof.Satish V. Kailas (Hall 3)
Prof. E. Raghu (Hall 4)
Parallel session
10.30 AM – 11.00 AM
10.30 AM – 11.00 AM
SESSION C: ORAL PRESENTATION: 11.00 AM – 1.00 PM (10 mts.for each presentation; TOTAL: 12/session)
Session C1,
Session C2, Metal
Session C3,
Session C4,
Session C5,
Session C6,
Machining
Forming
Joining/Welding
Advanced
Industrial
Miscellaneous
Manufacturing - I
Engineering &
Operations research
12 papers
6 papers
5 papers
12 papers
12 papers
3 papers
Session C2,
Session C3, Rapid
Session C6,
Prototyping
Casting
Materials Science
6 papers
6 papers
5 papers
1.00 PM – 2.00 PM
LUNCH
Prof. P.M. Pandey (Hall 1)
Dr. R. Balasubramaniam (Hall 2)
Parallel session
2.00 PM – 2.30 PM
2.00 PM – 2.30 PM
Dr. V.K. Suri (Hall 3)
Dr.DipayanSanyal (Hall 4)
Parallel session
2.30 PM – 3.00 PM
2.30 PM – 3.00 PM
SESSION D: ORAL PRESENTATION: 3.00 PM – 7.00 PM (10 mts. for each presentation; TOTAL: 24/session)
Session D1,
Session D2,
Session D3,
Session D4,
Session D5,
Session D6,
Machining
Composite
Advanced
Advanced
Industrial
Metrology
fabrication
Manufacturing - II
Manufacturing - I
Engineering &
Operations research
24 papers
24 papers
24 papers
24 papers
5 papers
3 papers
Session D5, Design
Session D6,
Materials Science
12 Papers
6 papers
GALA DINNER
8.00 PM – 10.00 PM
DAY 3: DECEMBER 14
Prof. Mustafizur Rahman (Hall 1)
Prof. Marc Madou (Hall 2)
Parallel session
9.00 AM – 9.30 AM
9.00 AM – 9.30 AM
SESSION E: ORAL PRESENTATION: 9.30 AM – 12.00 NOON (10 mts. for each presentation; TOTAL: 15/session)
SESSION E1,
SESSION E2, Advanced
SESSION E3, Machine tool design
Machining
Manufacturing - I
14 papers
15 papers
4 papers
SESSION E3, Tribology
4 papers
SESSION F: POSTER PRESENTATION (Posters 60-120)
12.00 NOON – 1.00 PM
LUNCH
1.00 PM – 2.00 PM
Dr. Ramesh Kumar (Hall 1)
Prof.VinodYadava (Hall 1)
Industrial talk by Taylor Hobson
2.00 PM – 2.30 PM
2.00 PM – 2.30 PM
2.30 PM – 3.00 PM
VALEDICTORY FUNCTION
3.30 PM – 4.30 PM
Parallel session
END OF AIMTDR 2014; GOOD BYE
-
AIMTDR 2014, DECEMBER 12-14, 2014
Schedule for Oral and Poster presentations
SESSION
SESSION A: ORAL PRESENTATION
Session A1, Machining (18)
Dec 12, 2014; 2.30-5.30 PM
Session A2, Metal Forming (18)
Dec 12, 2014; 2.30-5.30 PM
Session A3, Joining/Welding (18)
Dec 12, 2014; 2.30-5.30 PM
Session A4, Advanced Manufacturing – I
(19)
Dec 12, 2014; 2.30-5.30 PM
Session A5, Industrial Engineering &
Operations research (18)
Dec 12, 2014; 2.30-5.30 PM
Session A6, Miscellaneous (18)
Dec 12, 2014; 2.30-5.30 PM
SESSION B: POSTER PRESENTATION
(60)
Dec 12, 2014; 5.30-6.30 PM
SESSION C: ORAL PRESENTATION
Session C1, Machining (12)
Dec 13, 2014; 11.00 AM – 1.00 PM
Session C2, Metal Forming (6)
Session C2, Casting (6)
Dec 13, 2014; 11.00 AM – 1.00 PM
Session C3, Joining/Welding (5)
Session C3, Rapid Prototyping (6)
Dec 13, 2014; 11.00 AM – 1.00 PM
Session C4, Advanced Manufacturing – I
(12)
Dec 13, 2014; 11.00 AM – 1.00 PM
Session C5, Industrial Engineering &
Dec 13, 2014; 11.00 AM – 1.00 PM
Session C6, Miscellaneous (3)
Session C6, Materials Science (6)
Dec 13, 2014; 11.00 AM – 1.00 PM
SESSION D: ORAL PRESENTATION
Session D1, Machining (24)
Dec 13, 2014; 3.00 PM – 7.00 PM
Session D2, Composite fabrication (24)
Dec 13, 2014; 3.00 PM – 7.00 PM
Session D3, Advanced Manufacturing –
II (24)
Dec 13, 2014; 3.00 PM – 7.00 PM
Session D4, Advanced Manufacturing – I
(24)
Dec 13, 2014; 3.00 PM – 7.00 PM
Session D5, Industrial Engineering &
Session D5, Design (12)
AIMTDR PAPER NUMBERS, AIMTDR-O0XXX (XXX is
given below); NOTE: 10 MINUTES FOR EACH ORAL
PRESENTATION
20, 25, 50, 51, 67, 74, 84, 89, 90, 104, 108, 109,
124, 125, 127, 133
66, 94, 101, 122, 192, 194, 261, 280, 300, 318,
469, 470, 487, 496, 502, 511
27, 28, 34, 40, 80, 119, 164, 165, 170, 249, 297,
401, 409, 475, 486, 530
19, 29, 31, 42, 45, 48, 49, 79, 97, 99, 102, 107,
151, 152, 155, 174, 809
112, 116,
353, 378,
301, 379,
130, 132,
11, 21, 36, 53, 57, 69, 106, 126, 138, 139, 169, 201, 216,
320, 324, 384, 406, 418
8, 46, 56, 58, 118, 278, 304, 362, 366, 389, 458, 494, 557,
607, 633, 689, 698, 705
64, 70, 73, 146, 168, 177, 221, 282, 290, 291, 351, 356, 428,
473, 543, 576, 577, 688, 699, 802, 433, 587, 703, 157, 427,
631, 497, 654, 186, 211, 258, 283, 302, 495, 513, 528, 596,
617, 100, 148, 149, 150, 220, 234, 257, 296, 342, 360, 400,
443, 452, 508, 531, 561, 602, 606, 630, 643, 862, 417
135, 137, 159, 176, 193, 223, 252, 262, 269, 271, 275, 277
525, 575, 594, 650, 664, 808 156, 163, 346, 451, 524, 818
563, 589, 674, 814, 836
123, 189, 246, 399, 468, 507
178, 180, 182, 199, 204, 222, 231, 236, 266, 272, 295, 309
419, 463, 467, 474, 532, 534, 542, 547, 635, 641, 649, 683
706, 869, 98
110, 263, 471, 522, 609,55
306, 308, 310, 311, 312, 314, 325, 336, 338, 363, 369, 370,
375, 387, 388, 398, 405, 420, 423, 449, 454, 459, 461, 464
13, 38, 54, 173, 183, 245, 256, 289, 298, 315, 344, 345, 429,
481, 500, 506, 550, 601, 625, 648, 701, 801, 828, 832
22, 30, 32, 37, 52, 224, 229, 255, 331, 337, 361, 377, 380,
436, 462, 541, 624, 634, 657, 708, 875, 878, 233, 619
327, 332, 333, 334, 339, 341, 347, 371, 376, 381, 382, 390,
393, 394, 404, 413, 414, 422, 426, 430, 478, 490, 535, 536
812, 825, 837, 873, 635
71, 196, 238, 305, 321, 355,
666, 670, 687, 707, 838, 859
Dec 13, 2014; 3.00 PM – 7.00 PM
Session D6, Metrology (3)
Session D6, Materials Science (5)
Dec 13, 2014; 3.00 PM – 7.00 PM
SESSION E: ORAL PRESENTATION
SESSION E1, Machining (14)
Dec 14, 2014; 9.30 AM – 12 Noon
SESSION E2, Advanced Manufacturing
– I (14)
Dec 14, 2014; 9.30 AM – 12 Noon
SESSION E3, Machine tool design (4)
SESSION E3, Tribology (4)
Dec 14, 2014; 9.30 AM – 12 Noon
SESSION F: POSTER PRESENTATION
(60)
Dec 14, 2014; 12.00 NOON–1.00 PM
60, 810, 874
610, 622, 696, 844, 858
472, 477, 516, 556, 566, 582, 608, 653, 659, 685, 831, 854,
876, 877
537, 540, 559, 562, 564, 615, 618, 637, 661, 702, 704, 820,
822, 823
62, 391, 667, 806
12, 117, 416, 554
242, 299, 395, 480, 103, 128, 203, 581, 171, 386, 632, 141,
190, 510, 560, 815, 645, 105, 207, 465, 565, 572, 600, 651,
673, 676, 498, 61, 72, 209, 214, 247, 352, 445, 482, 517,
519, 527, 552, 567, 568, 570, 584, 585, 620, 640, 642, 644,
646, 292, 396, 425, 439, 450, 489, 504, 555, 578, 590, 623
Contents
Invited talks
57-116
Abstract on Machining
Paper
S. No. Number
AIMTDR–
O0020
1. 1
2.
O0025
3.
O0050
4.
O0051
5.
O0064
6.
7.
8.
O0067
P0070
O0073
9.
O0074
10.
O0084
11.
O0089
12.
O0090
13.
O0104
14.
O0108
117-159
Title
Analysis of Surface Roughness in Turning with Coated Carbide
cutting Tools: Prediction Model and Cutting Conditions Optimization
A. J. Makadia and J. I. Nanavati
Turning of Hardened H13 Steel with Interrupted and Continuous
Surfaces using Multilayer Coated Carbide Tool
R. Suresh and S. Basavarajappa
Preliminary Experimental Investigation on Multi-tool Turning Process
R. Kalidasan, M. Yatin, S. Senthilvelan and D.K. Sarma
Experimental Comparative Study of Conventional and MicroTextured Tools during Machining of AISI 1040 Alloy Steel
Rokkham Pavan Kumar Reddy, Kishor Kumar Gajrani and M. Ravi
Sankar
Surface Texturing by Using Patterned Grinding Wheel
Do Sup Han, Kang Qui, Tae Jo Ko and J.K. Park
An Effective Method to Determine the Optimum Parameters for
Minimum Quantity Lubrication (MQL) Grinding
Dinesh Setti, Sudarsan Ghosh and P Venkateswara Rao
Optimal Selection of Parameters in Multi Tool Drilling by Improved
Harmony Search Algorithm
V.Durga Prasada Rao, A.Balakrishna and V.Sai Surendra
Evaluation of Structural Geometry for Mini Milling Machine by
Boolean-algebra Technique
S.B.Chandgude and S.S.Patil
Determining Cutting Force Coefficients from Instantaneous Cutting
Force in Ball-End Milling
Mithilesh Kumar Dikshit, Asit Baran Puri, Atanu Maity and Amit Jyoti
Banarjee
An Experimental Investigation on End Milling of Si3N4
V.Krishnaraj and P.Kuppan,
Modeling and Optimization of Milling Parameters on Al-6061 Alloy
using Genetic Algorithm
Rishi Kumar, M. K. Pradhan and Rajesh Kumar
Modeling and Optimization of End Milling Parameters on Aluminum
6061 Alloy using GRA based Taguchi Method Coupled with PCA
Rishi Kumar, M. K. Pradhan and Rajesh Kumar
HSS Tool Wear Mechanism in Machining of HTBP based Composite
Propellant Grain
Kishore Kumar Katikani, Vanapalli Srinivasa Rohit , Anne Venu Gopal
and V.V.Rao
Effect of Direct and Indirect Cryogen Application Methods on the
Turning Forces, Tool Wear and Surface Finish of a Nickel Based Alloy
(Nimonic 90)
15.
O0109
16.
O0112
17.
O0116
18.
O0124
19.
O0125
20.
O0127
21.
O0133
22.
O0135
23.
O0137
24.
O0146
25.
O0159
26.
O0168
27.
O0176
28.
O0177
29.
O0193
30.
O0221
Chetan, Bikash Chandra Behera, Sudarsan Ghosh and P Venkateswara
Rao
Application of Taguchi Method for Optimizing Material Removal Rate in
Turning of En-47 Spring Steel
Yogendra Kumar and Hari Singh
Process Parameter Optimization in Multi-Pass Turning Operation using
Hybrid Firefly Swarm Algorithm
R.Gayatri, N.Baskar and M.Malarvizhi
Effects on Forces and Surface Roughness During Machining
Inconel 718 alloy Using Minimum Quantity Lubrication
Bikash Chandra Behera, Chetan, Sudarsan Ghosh and P Venkateswara
Rao
Performance Evaluation of CVD Multilayer Coating on Tool Wear
Characteristics during Dry Machining of Nimonic C-263
A.Thakur, S.Gangopadhyay, A. Mohanty and K.P.Maity
An Experimental Study on Green Machining
P. Saikia and M.Hazarika
Effect of Process Parameters on Convective Heat Transfer Coefficient of
Fluid and Heat Partitioning in High Efficiency Deep Grinding with
Water based Coolant
M. Vashista and S. Paul
Surface Integrity and Optimization in Turning Ti6Al4V
Satyanarayana.K, Ravi.N , Shivaji Babu.K and Venu Gopal.A
3-D Finite Element Modeling of Thin-Wall Machining of Aluminum
7075-T6 Alloy
Gururaj Bolar and S. N. Joshi
Selection of Machining Parameters in Face Milling Operations for
Copper Work Piece Material Using Response Surface Methodology
and Genetic Algorithm
S. Kannan, N. Baskar and B. Suresh Kumar
An Investigation into Selection of Optimum Dressing Parameters based
on Grinding Wheel Grit Size
Manoj Kumar Sinha, Dinesh Setti, Sudarsan Ghosh and P Venkateswara
Rao
An Effective Grinding Fluid Delivery Technique to Improve
Grindability of Inconel-600
Anirban Sarkar, Bijoy Mandal, Debashis Biswas, Santanu Das and
Simul Banerjee
Development of a Portable Intelligence Control System to Reduce
Components Dimensional Variations in Milling
N Ganesh Kumar and P Radhakrishnan
Optimization of Radial Force in Turning Process using Taguchi’s
Approach
Sumit Verma and Hari Singh
Experimental Investigation on Surface Roughness Characteristics in
Hard Turning of EN31 Steel using Coated Carbide Insert: Taguchi and
Mathematical Modeling Approach
Panda, A., Dutta, S.K., Sahoo, A.K., Rout, A.K.and Routra, B.C.
Integrated Strategies for High Performance Peripheral Milling
M.Law, M.Wabner and S. Ihlenfeldt
Utility Fuzzy Multi Objective Optimization of Process Parameters for
CNC Turning of GFRP/Epoxy Composites
Hari Vasudevan, Naresh Deshpande, Ramesh Rajguru and Sandip Mane
31.
O0223
32.
O0252
33.
O0262
34.
O0269
35.
O0271
36.
O0275
37.
O0277
38.
O0282
39.
O0290
40.
O0291
41.
O0306
42.
O0308
43.
O0310
44.
O0311
45.
O0312
46.
O0314
47.
O0325
48.
O0336
49.
O0338
Experimental Investigation and Optimization of Milling Parameters in the
Machining of NEMA G-11 GFRP Composite Material using PCD Tool
Hari Vasudevan, Ramesh Rajguru, Naresh Deshpande and Sandip Mane
An Expert System for Selection of Carbide Cutting Tools for
Turning Operation
P. D. Chougule, S. Kumar and H. K. Raval
Comprehensive Study of Chip Morphology in Turning of Ti-6Al-4V
Vikas Upadhyay, P.K. Jain and N.K. Mehta
NN-GA Based Modeling and Optimization of Cylindrical Grinding
Process
R.Rekha and N.Baskar
A Fuzzy Logic Model to Evaluate Thrust Force in the Drilling of
Medium Density Fiber Board
S.Prakash, J.Lilly Mercy Dhrubajyoti Baruah and Putti Venkata Siva
Teja
Multi Characteristics Optimization using Taguchi Quality Loss Function
with Varying the Weightage of Responses in Drilling of GFRP Composite
Sunil Hansda and Simul Banerjee
Investigation of Ionic Liquids as Metalworking Fluids in Minimum
Quantity Lubrication Machining of AISI1045 Steel
G. S. Goindi, S. N. Chavan, D. Mandal P. Sarkar and A. D. Jayal
Mathematical Modeling and Statistical Analysis of Delamination in the
Drilling of Particle Board Wood Composite
J. Lilly Mercy, S.Prakash, Kaushik Goswami and P. Vijayalakshmi
Comparison between PVD Coated and Uncoated Carbide Tools While
Machining Aluminium Alloy – 6063
U. Ashok Kumar, N. Saidulu and P. Laxminarayana
Friction Surfacing Process of Aluminum Alloys
U. Ashok Kumar and P. Laxminarayana
Comparison of Dimensional Repeatability and Accuracy for Deformation
Machining Stretching Mode with Sheet Metal Components
Arshpreet Singh and Anupam Agrawal
Experimental Investigations of Surface Texture in Conventional and
Modulation Assisted Drilling of Stainless Steel 316
Ravinder Singh Joshi and Harpreet Singh
Modeling of GD&T Requirements of Crankshaft flange using DOE
Jayalakshmi, P.M George and S.P Joshi
Modeling and Optimization of Surface Roughness in Surface Grinding of
SiC Advanced Ceramic Material
Binu Thomas, Eby David and Manu R
Investigation of Surface Textured Cutting Tools for Sustainable Machining
S. B. Dhage, P. Sarkar and A. D. Jayal
An Experimental Investigation on Drilling of CFRP/Ti stacks using
Minimal Flow Lubricating- (MFL) Technique using Coated (TiAlN) and
Uncoated Drills
SenthilKumar, M., Prabukarthi, A. and Krishnaraj, V.
Optimisation of Hard Turning of M42 Tool Steel Using PCR-Topsis
Method
Sagar P. Bhise, P.D. Pantanwane and B. Rajiv
Experimental Investigation on Cutting Force and Surface Roughness in
Machining of Hardened AISI 52100 Steel using CBN Tool
Sudhansu Ranjan Das, Debabrata Dhupal and Amaresh Kumar
Optimization of Machining Parameters during End Milling of GFRP
Composites by Desirability Function Analysis using Taguchi Technique
50.
O0351
51.
O0356
52.
O0363
53.
O0369
54.
O0370
55.
O0375
56.
57.
58.
59.
60.
61.
O0387
O0388
O0391
O0398
O0405
O0420
62.
O0423
63.
O0428
64.
O0449
65.
66.
O0454
O0459
Sreenivasulu Reddy
Optimization of Material Removal Rate and Surface Roughnessin WEDMachining of TiNi SMA using Grey Relation Analysis
Manjaiah, M., Narendranath, S. and Basavarajappa, S.
Cryogenic Machining of SS304 Steel
Sunil Magadum, S. Arun Kumar, V. G. Yoganath and C.K.Srinivasa
Role of MQL and Nano Fluids on the Machining of Nicrofer C263
Subhash Chandra Bose, C S P Rao and Kishore Jawale
Multi Response Optimization of Machining Parameters in High Speed
Machining of Y-ZTA Insert using Desirability Function Approach of
Response Surface Methodology (RSM)
Mandal Nilrudra, Doloi, B. and Mondal, B.
An Experimental Investigation of Hot Machining Performance Parameters
using Oxy-Acetylene Gas Setup
Venkatesh Ganta and D. Chakradhar
Investigation on the Influence of Cutting Parameters on Machine tool
Vibration & Surface Finish using MEMS Accelerometer in High Precision
CNC Milling Machine
N. Kusuma, Megha Agrawal and P.V.Shashikumar
Potential of Vegetable Oils as Micro Lubrication / Cooling Medium for
SQL-Grinding
Manoj Kumar K, Jeewan Sarda and Amitava Ghosh
Performance of MoS2 Spray Coated End Mills in Reduction of Built-up
Edge Formation (BUE) in Machining Aluminium
Suresh Kannan I, Sandip Baul and Amitava Ghosh
Design and Evaluation of a Novel Machine Bed with Adjustable Pin
Configuration to Minimize Damage during Sheet Metal Cutting Processes
K. Vijay Anand and A. Ramesh Babu
Experimental Studies on the Grinding of Ti-6Al-4V using Micro and
Nano Size Solid Lubricants
A. K. Malik, S. Ghosh and R. K. Pandey
Performance Evaluation of Tin Coated and Uncoated Carbide Tools in
Turning AISI 4140 Steel
Pratik L. Nagalwade and A. V. Kale
Finite Element Analysis of Workpiece Temperature during Surface
Grinding of Inconel 718 Alloy
Chahat Sharma, Sudarsan Ghosh and Prabal Talukdar
Comparative Evaluations of Tool Nose Wear Progression under Dry and
Near-dry Cutting Conditions during Hard Turning through
Experimentation and Mathematical Modeling
Satish Chinchanika and S.K. Choudhury
FEM Analysis on Residual Stresses Induced in Dry Turning: A Review
A.K. Mishra and P. Shandilya
Performance Evaluation of Ordinary and Wiper Inserts in Dry Turning of
Inconel 718 Super Alloy using Grey-Fuzzy Algorithm – A Hybrid
Approach
K. Venkatesan, R.Ramanujam, Vimal Saxena and Rachit Pandey
Investigation on Influence of Refrigerated Air and High Heat Transfer
Rate MQL in Turning of Aluminum Metal Matrix Composite
N.V.V.S. Sudheer, K.V.J.Rao and V.Chittaranjan Das
Correlation among the Cutting Parameters, Surface Roughness and Cutting
Forces in Turning Process by Experimental Studies
R. Jithin Babu and A.Ramesh Babu
67.
68.
O0461
O0464
69.
O0472
70.
O0473
71.
72.
73.
O0477
O0516
O0543
74.
O0556
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
O0566
O0577
O0582
O0608
O0653
O0685
O0688
O0699
O0802
O0831
Experimental Investigation and Analysis of Machining Characteristics in
Drilling Hybrid Glass-Sisal-Jute Fiber Reinforced Polymer Composites
M.Ramesh, K.Palanikumar, K.Hemachandra Reddy
Empirical Modeling of Cutting Forces in Ball End Milling using
Experimental Design
M.N.M. Venkateswara Sarma and R. Manu.
Form Error Correction of Bevel Gears by Electrochemical Honing Process
Shaikh Javed Habib and Neelesh Kumar Jain
Evaluation and Comparison of Machinability Characteristics of
Maragining Steel and AISI 304 Steels
Rangilal Bhukya, C.S.P. Rao and G.V.Rao
Isophote Based Tool Path Planning Strategy for Sculptured Surface CNC
Machining
Aniket Anil Chaudhary and S.S. Pande
Behavior of Cutting Forces Considering Effect of Tool Wear on Principal
Flank, Auxiliary Flank and Rake Faces: Individually and in Combination
Amarjit Prakashrao Kene and S.K. Choudhury
Experimental Evaluation and Optimization of Dry Drilling Parameters of
AISI304 Austenitic Stainless Steel Using Different Twist Drills
Nayan G Kaneriya and Gaurav Kumar Sharma
Effect of Carburizing Flame and Oxidizing Flame on Surface Roughness
in Turning of Al/SiC MMC and Teaching-Learning-Based Optimization of
Process Parameters
N. V. V. S.Sudheer and K. KarteekaPavan
Thermal Stress Prediction within the Contact Surface during Creep Feed
Deep Surface Grinding
Audhesh Narayan, and Vinod Yadava
Prediction of Surface Roughness on Dry Turning using Two Different
Cutting Tool Nose Radius
Uddipta Gautam, Sanghamitra Das and D.K.Sarma
Performance Analysis of Cylindrical Grinding Process
with a Portable Diagnostic Tool
R. Vairamuthu, M Brij Bhushan, R. Srikanth and N. Ramesh Babu
Application of Artificial Neural Network for Modelling Surface
Roughness in Centerless Grinding Operation
S. C.Mondal and P. Mandal
Desirability Analysis and Genetic Algorithm Approaches to Optimize
Single and Multi Response Characteristics in Machining Al/SiCp MMC
M. Chandrasekaran and Santosh Tamang
An Experimental Investigation into the Applicability of Boric Acid as
Solid Lubricant in Turning AISI 4340 Steel
APS Gaur and Sanjay Agarwal
Combine Approach for Studying the Parametric Effects on Quality
ofHoles Using RSM and PCAfor Drilling of AISI-304 Stainless Steel
Suman Chatterjee, Arpan Kumar Mondal and Siba Sankar Mahapatra
Study and Optimization of Parameters for Optimum Cutting Condition
During Turning Process Using Response Surface Methodology
Shivraj Singh Harvinder Singh and Harry Garg
Optimisation of Process Parameters in Turning of Grey Cast iron with
Mixed Oxide Ceramic Tool using Taguchi’s Approach
S.K. Rajbongshi, A. Borah, P.K. Choudhury
An Experimental Study on the Burr Formation in Drilling of
AluminumChannels of Rectangular Section
Ratnakar Das and Tarakeswar Barik
85.
86.
87.
O0854
O0876
O0877
Effect of Tool Wear on White Layer Thickness and Subsurface Hardness
on Hard Turned EN31 Steel
Gaurav Bartarya and S.K.Choudhury
A Study on the Minimum Quantity Lubrication in Grinding of Titanium
Alloy (Ti-6Al-4V)
Monith Biswojyothi, A.S.S.Balan, N.Arunachalam and L.Vijayaraghavan
An Approach to Development of Involute Spline on Large Parts using
CNC Machining
A.Velayudham, Prasmit,Kumar Nayak and A.M. Junaid Basha
Abstract on Machine Tool Design
88.
O0433
89.
O0587
90.
91.
O0667
O0806
Effect of Sleeve Shrink-fit on Bearing Preload of a Machine Tool
Spindle: Analysis using Finite Element Method
Aslam Pasha Taj and S. R. Chandramouli
DIY CNC: A Review
Dhaval B. Patel and Aniruddh R. Kyada
Optimization of Cutting Tool Geometry by CAE Approach for Titanium
Alloy
K. Pradeep Kumar Mouli, Srinivasa Rao Nandam, P. Vijay Kumar
Raju, G. Appala Raju and A.Chandrakanth
Experimental Modal Analysis (EMA) of a Spindle Bracket of a
Miniaturized Machine Tool (MMT)
K.Rajesh Babu and G. L.Samuel
Abstract on Metal Forming
92.
93.
O0066
O0094
94.
O0101
95.
O0122
96.
O0157
97.
O0192
98.
O0194
99.
O0280
100.
101.
102.
103.
O0300
O0318
O0353
O0378
161-164
165-178
An Efficient Inverse Method for Determining the Material Parameters
and Coefficient of Friction in Warm Rolling Process
V. Yadav, A.K. Singh and U.S. Dixit
Design and Development of Single Point Incremental Sheet Forming
Machine
Yogesh Kumar and Santosh Kumar
Review of Rubber Based Sheet Hydro-forming Processes
Abhishek Kumar, Santosh Kumar and D. R. Yadav
Feasibility Study of Thermal Autofrettage Process
S. M. Kamal and U. S. Dixit
Implementing the Genetic Methodology with VLSI Approach for
Optimization Of Sheet Metal Nesting
K.Ramesh and N.Baskar
Control of Ovality in Pipe Bending: A New Approach
A. V. Kale and H. T. Thorat
Studies on Effect of Feedstock Temperature in Continuous Extrusion
Devendra Kumar Sinha and Santosh Kumar
Exploring Forging Load in Closed-Die Forging
D. Sheth, Santanu Das, A. Chatterjee and A. Bhattacharya
Influence of Adhesive on the Spring Back of Adhesive Bonded Sheets
Avinash Kumar Yadav, Ram Nivas, Ravi Kumar and R. Ganesh
Narayanan
Spring Back of Friction Stir Welded Sheets: Experimental and Prediction
Sudhindra Katre, Siddhartha Karidi and R. Ganesh Narayanan
Effect of Yield Strength, Pre-strain and Curvature on Stiffness and Static
Dent Resistance of Formed Panel
G Manikandan, Rahul K. Verma and Abhishek Raj
Modelling of the Transformation of Coarse Grained Microstructure of
+ Titanium Alloys along with FEM Simulation of Hot Forming
104.
105.
O0427
O0469
106.
O0470
107.
108.
O0487
O0496
109.
O0502
110.
111.
O0511
O0525
112.
O0575
113.
114.
115.
O0594
O0631
O0650
116.
O0664
117.
O0808
Processes
M.K.Sarangi, S.K.Mandal, B.K.Pradhan P.V.Chistyakov, R.A.Vasin
O.I.Bylya and P.L.Blackwell
Investigation of Forming Behavior Prediction of Different Steel Grade
Materials using Numerical Simulation
Sudhir Chakravarthy Katragadda, Shaik Salkin Basha and Perumalla
Janaki Ramulu
Formability Studies on Aluminum Alloy Sheets through Deep Drawing
Process
U. Pranavi, P. Venkateshwar Reddy and Perumalla Janaki Ramulu
Experimental and Numerical Investigations on the Effect of Weld Zone
on Springback in V-Bending of Tailor Welded Blanks of High Strength
Steel
Vijay Gautam and D. Ravi Kumar
Finite Element Analysis of Cross Rolling on AISI 304 Stainless Steel:
Prediction of Stress and Strain Fields
M. Rout, S.K. Pal and S.B. Singh
Analysis of Warm Deep Drawing for Ti-6Al-4V Alloy
Nitin Kotkunde, Sachin Rane, Amit Kumar Gupta and Swadesh Kumar
Singh
Prediction of Forming Limit Curves for Extra Deep Drawn (EDD) Steel
using Marciniak and Kuczynski (MK) Model
Sashank Srinivasan, Geetha Krishna A., Shyam Krishna Shenoy A,
Swadesh Kumar Singh and Amit Kumar Gupta
Characterization of Mechanical Properties and Formability of Cryorolled
Aluminium Alloy Sheets
Fitsum Taye,Purnendu Das, D. Ravi Kumar and B. Ravi Sankar
Improvement in Accuracy of Failure Prediction in FE Simulations of
Sheet Metal Forming of Al Alloys
B Prajeesh, D Raja Satish and,D Ravi Kumar
Prediction of Formability of Bi-axial Pre-strained Dual Phase Steel
Sheets Using Stress Based Forming Limit Diagram
Shamik Basak, Kaushik Bandhyopadhay, Sushanta Kumar Panda and
Partha Saha
Formability Studies on Aluminum Alloy Sheets through Deep Drawing
Process
U. Pranavi, P. Venkateshwar Reddy and Perumalla Janaki Ramulu
A Review on Micro-Extruded Microstructure from Ultra-fine Grained
and as Cast
Pintu Kumar and Sudhansu Sekhar Panda
On the Reduction of High Starting Load in Cold Drawing of Circular
Tubes
G. Mathan, G.Manikandan, Abhishek Raj and Ashish P. Rajgure
Effect of Process Parameters on the Mean Diameter of AA 6082 Flow
Formed Tubes - An Experimental Investigation
M. Komaraiah, M. Srinivasulu and C.S. Krishna Prasada Rao
Application of a New Friction Model in Circular Cup Drawing
Ravindra K. Saxena and Anuj Sharma
Abstract on Casting
118.
O0156
179-183
Automated Vision Inspection System for a Plastic Injection Mould
Component
R. Deepa, S. Usha and P. V. Shashi Kumar
119.
120.
121.
122.
123.
124.
O0163
O0346
O0451
O0524
O0654
O0818
Computer Aided Runner and Gating System Design from Die-Casting
Part Model
Ranjit Singh and Jatinder Madan
Investigations of Physical Properties of A356/Al2O3/Graphite Stir with
Squeeze Casting Method
G.Nagesh, V. Sukesha, Rajeev Ranjan and K.Sekar
Mathematical Modelling of Solidification in a Curved Strand during
Continuous Casting of Steel
Ambrish Maurya and Pradeep Kumar Jha
A Numerical Study of Mold Filling in Microcasting
Sateesh Kumar Yadav, Rajesh Kumar Shukla and Arvind Kumar
Experimental Investigations on The Microstructure of Aluminium 6063
with Copper and Gun Metal
Tony Thomas, R. Kirubha Parameshwaran and K. S. Sre Nandha
Guhan
Computer-Aided System for Multi-Cavity Die-Casting Die-Design
V. Kumar and J. Madan
Abstract on Joining
125.
O0034
126.
127.
O0040
O0080
128.
O0119
129.
130.
131.
132.
133.
134.
O0164
O0165
O0170
O0186
O0211
O0249
135.
O0258
136.
O0297
185-201
Prediction of Weld Induced Angular Distortion of Single Sided and
Double Sided Fillet Joint by SAW Process
Arpan Kumar Mondal, Pankaj Biswas, Swarup Bag and Manas M.
Mohapatra
Optimization of Process Parameters in Submerged Arc Welding using
Multi-objectives Taguchi Method
A. Saha and S. C. Mondal
Characterization and Optimization of Weld Strength of Dissimilar Metals
A. P. Tadamalle, Y. P. Reddy, E. Ramjee and K. V. Reddy
Effect of Shoulder Diameter and Plunging Depth on Mechanical
Properties and Thermal History of Friction Stir Welded Magnesium
Alloy
Prakash Kumar Sahu and Sukhomay Pal
Monitoring of Friction Stir Welding Process through Signals Acquired
during the Welding
Bipul Das, Sukhomay Pal and Swarup Bag
Effect of Preheating on Mechanical Properties of Hybrid Friction Stir
Welded Dissimilar Joint
Deepak Kumar Yaduwanshi, Sukhomay Pal and Swarup Bag
A Study on Tooling and Its Effect on Heat Generation and Mechanical
Properties of Welded Joints in Friction Stir Welding
Sujoy Tikader, Pankaj Biswas and Asit Baran Puri
Parametric Studies and Finite Element Analysis of Steel in Resistance
Spot Welding process
N.Kishore, S.Sreenu, N.Ramachandran and K.Allesu
Estimation of Weld Pool Geometry and Cooling Rate in Laser Welding
A. P. Tadamalle, Y. P. Reddy, E. Ramjee and K. V. Reddy
Coupled Electromagnetic Structural Simulation of Magnetic Pulse
Welding
Angshuman Kapil and Abhay Sharma
Investigation of Recycled Slag in Submerged Arc Welding for Pressure
Vessels
S. B. Chandgude and S. S. Asabe
Effect of Process Parameters on Tensile Properties of Friction Stir
Welded Joints
137.
138.
139.
140.
O0301
O0302
O0379
O0401
141.
O0409
142.
O0475
143.
O0486
144.
O0495
145.
O0513
146.
O0528
147.
O0530
148.
149.
150.
151.
152.
153.
154.
O0563
O0589
O0596
O0617
O0674
O0814
O0836
Biswajit Parida and Sukhomay Pal
CAFE Modelling to Predict the Grain Size during Friction Stir Welding
of Aluminium Grades
Sharad Valvi, Sumitesh Das and R. Ganesh Narayanan
3Resistance Welding of Austenitic Stainless Steels (AISI 304 with AISI
316)
A.B.Verma, S.U. Ghunage and B.B. Ahuja
Experimental Study on Temperature Evolution during Friction Stir
Welding of 6061-T6 Aluminum Alloy
Perumalla Janaki Ramulu and R. Ganesh Narayanan
Effect of Process Parameters on Angular Distortion of MIG Welded
AI6061 Plates
S. Ramani and V. Velmurugan
Application of Genetic Algorithm to Optimize Properties of Pulsed
Current Micro Plasma Arc Welded Inconel 625 Sheets
Kondapalli Siva Prasad, Chalamalasetti Srinivasa Rao, Damera
Nageswara Rao and Chintala Gopinath
Mechanical and Microstructural Characterization of Friction Stir Welded
Al-Si-Mg Alloy
Vikas Sharma, Shailendra Singh, Chaitanya Sharma and Vikas
Upadhyay
Finite Element Simulation of Temperature and Strain Distribution in
Al2024 Aluminum Alloy by Friction Stir Welding
Rahul Jain, S.K. Pal and S.B. Singh
Study on the Novel Twin-Tool System in Friction Stir Welding Process
Kanchan Kumari, S.K. Pal and S.B.Singh
Regression Modeling and Process Analysis of Resistance Spot Welded
Joints
S. Sreenu, N. Kishore, N. Ramachandran and K. Allesu
Parametric Analysis of Friction Stir Welding
Suyash Tiwari, H. Chelladurai and Ashish Kumar Shukla
Numerical Analysis of Heat Transfer in Arc Welded Plate
Aniruddha Ghosh, Pawan Kumar and Arvind Kumar
Development and Analysis of Butt and Lap Welds in Micro Friction Stir
Welding (µFSW)
Shuja Ahmed, Abhishek Shubhrant, Akash Deep and Probir Saha
Effect of Different Experimental Parameters Observation Through
Simulation of Tailor Welded Blanks Made of Friction Stir Welding
Aruna Jyothi, Monika Sharma and Perumalla Janaki Ramulu
Prediction of Bead Reinforcement Height and Width of Gas Tungsten
Arc Welded bead-on Plate Joints Using Artificial Neural Network
Rajeev Kumar, Somnath Chattopadhyaya and Sanjeev Kumar
Evolution of Temperature Field Developed in Arc Welded Steel Butt
Joints and its Effect on Cooling Rate: An Experimental and Mathematical
Approach
Jaideep Dutta and S. Narendranath
Experimental and Analytical Study of Thermally Induced Residual
Stresses for Stainless Steel Grade using GMAW Process
M.N.Chougule and S.C.Somase
Prediction of Weld Bead Geometry for Double Pulse Gas Metal Arc
Welding Process by Regression Analysis
Mainak Sen, Manidipto Mukherjee and Tapan Kumar Pal
Experimental Investigations on Plasma Arc Welding of Lean
Supermartensitic Stainless Steel
Birendra Kumar Barik, P. Sathiya and S.Aravindan
Abstract on Advanced Manufacturing-I
155.
156.
157.
158.
159.
160.
O0019
O0027
O0028
O0029
O0031
O0042
161.
O0045
162.
163.
164.
165.
166.
167.
168.
O0048
O0049
O0079
O0097
O0099
O0100
O0102
169.
O0130
170.
O0132
203-245
Optimization of Dimensional Deviation:Wire Cut EDM of Vanadis 4E
(Powder Metallurgical Cold Worked Tool Steel) by Taguchi Method
D.Sudhakara and G.Prasanthi
Prediction of Thermal History of Friction Stir Welding by Considering
Combined Stick & Slip Condition of AA1100
Arun Kumar Kadian, Gautam Puri and Pankaj Biswas
Effect of Tool Geometry and Process Parameters on the Material Flow of
Friction Stir Welding
Arun Kumar Kadian, Gautam Puri, Suman Das and Pankaj Biswas
Finishing of Synchrotron Beamline Mirrors
Ajay Sidpara, V. K. Jain and G. S. Lodha
Experimental Study into Groove Machining using Rotary Disk Electrical
Discharge Machining with Silicon Powder-mixed Dielectric
Shankar Singh and Anand Pandey
Thermal and Metallographic Investigation for H13A and AISI410 using
Vortex Tube Jet Assisted (VTJA) Machining
Balaji Nelge, Kiran Devade, A.T. Pise and V. M. Kale
Analysis of Magnetic Field Assisted Finishing (MFAF) Process
Parameters for Finishing Of Brass Workpiece Using Soft-Computing
Technique
Anwesa Barman, Chandan Kumar and Manas Das
Modeling and Simulation of Magnetic Field Assisted Finishing Process
Anwesa Barman, Manas Das and Ankur Singh
Modeling of Finishing Forces and Surface Roughness in Abrasive Flow
Finishing (AFF) Process Using Rheological Properties
Sachin Singh, M. Ravi Sankar,V. K. Jain and J. Ramkumar
Effect of Direct Current and Pulse Current on Processing Time,
Electrolyte
Composition
and
Electrolyte
Concentration
of
Electrochemical Honing
H. Singh and P.K. Jain
Investigation of Machining Characteristics of Electrochemical
Micromachining Machine (EMM)
R. Thanigaivelan, R. M. Arunachalam andN. Natarajan
Selection of Non-Conventional Manufacturing Process: A Combine
TOPSIS-AHP Approach
Ashish Chauhan and M. K. Pradhan
Multi-Response Analysis of Electro-Chemical Machining Process using
Principal Component Analysis
K. P. Maity and N. K. Verma
Fabrication of Complex Circuit Using Electrochemical Micro Machining
on Printed Circuit Board (PCB)
Jitendra Singh, V.K. Jain and J.R. Kumar
Simultaneous modeling of responses in AWJM of Borosilicate glass by
SVM and SEM study
Ushasta Aich, Simul Banerjee , Asish Bandyopadhyay and Probal
Kumar Das
Multi Objective Optimization of Cutting Parameters in Micro-milling of
Ti-6Al-4V Alloy
H. Sooraj and J. Mathew
171.
172.
173.
174.
175.
O0148
O0150
O0151
O0152
O0155
176.
O0174
177.
178.
179.
180.
181.
182.
183.
184.
185.
O0178
O0180
O0182
O0199
O0204
O0220
O0222
O0231
O0234
186.
O0236
187.
O0257
188.
O0266
Investigation of the Effects of Process Parameters on Material Removal
Rate & Tool Wear Rate during Wet & Near-dry EDM Process
P. Tripathy, K. P. Maity and B. Rajiv
Response Surface Modeling of Electric Discharge Machining Process
Parameters for EN 24 Low Alloy Steel
N. Annamalai, V. Sivaramakrishnan and N.Baskar
Fabrication of Disc Shaped Microtool by Electrochemical
Micromachining for Micromachining Applications
V. Rathod, B. Doloi and B. Bhattacharyya
Optimization of Electrical Discharge Machining Parameters using
Artificial Neural Network with Different Electrodes
V.Balasubramaniam, N.Baskar and C.Sathiya Narayanan
Optimization of the Quality and Productivity Characteristics of AISI P20
Tool Steel in EDM Process using PCA-based Grey Relation Analysis
S. Dewangan, C. K. Biswas and S. Gangopadhyay
Experimental Study of Material Removal Rate, Surface Roughness &
Microstructure in Electrochemical Machining of Inconel 825
A. Mohanty, Gangadharudu Talla, S. Dewangan and S.
Gangopadhyay
Nano-Groove Generation by Diamond Turn Machining and Chemical
Processing
Prabhat Ranjan, Anuj Sharma, R. Balasubramaniam and V.K. Suri
A Neuro-fuzzy Approach for Optimization of Multiple Responses in
Taper Cutting using Wire Electrical Discharge Machining
B.B. Nayak and S. S. Mahapatra
Experimental Investigations for Al2O3 Ceramic Micro Machining using
ECDM Process
Anjesh H Sahasrabudhe and B. B. Ahuja.
An Expert System for Non-traditional Machining Process Selection
Kanika Prasad and Shankar Chakraborty
Experimental Investigation of Ultrasonic Machining on Alumina BioCeramic for Stepped Hole Fabrication
S.Das, B. Doloi and B. Bhattacharyya
Artificial Neural Network Modeling for Prediction of Performance in
Abrasive Jet Drilling Process for Glass Material
J. R. Samani, H.S.Beravala, P. B. Jadav and C. J. Dusra
Experimental Investigations into Micro-drilling using Air Assisted Jet
Electrochemical Machining
Harsha Goel and Pulak M. Pandey
Investigation into Electrochemical Micromachining Process for
Fabricating 3-D Fine Patterns in Air Lubricated Bearing
S. Debnath, K. Bandopadhyay and B. Bhattacharyya
Experimental Investigation into Generation of Micro Hole on Titanium
by Electrochemical Micromachining
Sandip S. Anasane and B. Bhattacharyya
Computational Analysis for Mixing of Fluids Flowing through MicroChannels of Different Geometries
Sankha Shuvra Das, Binay Kumar Patawari, P.K. Patowari and S
Halder
Modeling of Wire Electrical Discharge Machining of AISI D3 Steel
using Response Surface Methodology
Brajesh lodhi and Sanjay agarwal
Performance of Monopole Concentrator during Microwave Drilling of
Perspex
189.
O0272
190.
O0295
191.
O0296
192.
O0309
193.
O0327
194.
O0332
195.
196.
197.
198.
O0333
O0334
O0339
O0341
199.
O0342
200.
O0347
201.
O0360
202.
O0371
203.
O0376
204.
205.
O0381
O0382
Nitin Kumar Lautre, Apurbba Kumar Sharma, Pradeep Kumar and
Shantanu Das
A Study on Wire Breakage and Parametric Efficiency of The Wire
Electro Chemical Discharge Machining Process
Amarinder Singh, C. S. Jawalkar, Rahul Vaishya and Apurbba Kumar
Sharma
Studies on Tool wear characteristics in Micro Electro Discharge Slotting
Process (µ-EDS)
Harshit Dave, Vishal Mathai, Mukul Mayanak, Harit Raval and Keyur
Desai
Electro Discharge Machining of AISI 304 Using Solid and Bundled
Electrodes
H. K. Dave, Sudhanshu Kumar, N. C. Rana and H. K. Raval
Modeling of Wire EDM slicing process for Silicon
Kamlesh Joshi, Gaurav Sharma, Ganesh Dongre and Suhas S. Joshi
Experimenta and Simulation of Three Dimensional Micro EDM with
Single and Multiple Discharges
Alwin Varghese, Basil Kuriachen, Satyananda Panda and Jose Mathew
Numerical Modeling and Multi-Objective Optimization of Micro-Wire
EDM Process
Dinesh Babu P.,Deepak G Dilip, Somashekhar K.P., Allesu K. and J.
Mathew
Modelling of Micro Electric Discharge Machining using FEM
S.Mithun Nair, K.Basil, R. Vijayakumar and Jose Mathew
Experimental and Finite Element Based Investigations on Powder Mixed
Micro-Electrical Discharge Machining of Ti-6Al-4V Alloy
V.Vipin, B.Kuriachen, R.Manu and J. Mathew
Experimental Study on Varying Electromagnetic Field Assisted
Die Sinking EDM
Vignesh S. Naidu, K. Vipindas, R. Manu and J. Mathew
Modeling and Multi-response Optimization of Micro EDM Drilling on
Inconel 718
B. Kuriachen and J. Mathew
Spark Radius Modeling of Micro Electric Discharge Machining of Ti6AL-4V
B. Kuriachen and J. Mathew
High Aspect Ratio Micro-features by Electrochemical Micromachining
B. Ghoshal and B. Bhattacharyya
A Study on Effect of EDM Process Parameters on AISI 304L Stainless
Steel
D. K. Ojha, S. Panda and D. Mishra
Investigation and Fuzzy based Modeling of Micro-EDM Process during
Machining of Micro-hole in D3 Die Steel Material Employing DEIonized Water
I. Shivakoti, G. Kibria and B.B. Pradhan
Electric Discharge Machinability Studies on D0403 and D0376 Alloy
Steels
S. Santosh, K. Rajkumar, S. Raghuraman, T. Panneerselvam and K.
Thiruppathi.
Investigations on Grinding of Inconel 718 using newly developed
Graphene Nano Platelets Impregnated Grinding Wheels
R. Bhanu Pavan, G. Bhanu Kiran, R.R. Srikant and A. Venu Gopal
Regression Model for Electro-Chemical aided Abrasive Flow Machining
(ECA2FM) Process
206.
207.
O0390
O0393
208.
O0394
209.
210.
211.
212.
213.
214.
215.
216.
217.
218.
219.
220.
221.
222.
O0400
O0404
O0413
O0414
O0422
O0426
O0430
O0443
O0452
O0478
O0490
O0531
O0535
O0536
B. S. Brar, R.S. Walia and V.P. Singh
Performance analysis of ball end magnetorheological finishing using
sintered magnetic abrasive based magnetorheological polishing fluid
Mahendra Singh Niranjan and Sunil Jha
Application of Grey Relational Analysis for Geometrical Characteristics
in Abrasive Water Jet Milled Channels
T. V. K. Gupta, J. Ramkumar, Puneet Tandon and N. S. Vyas
Tool Condition Monitoring using Multiple Sensors Approach in the
Microendmilling of Aluminium Alloy (AA 1100)
M. Prakash, M. Kanthababu, S. Gowri, R. Balasubramaniam and John
Rozario Jegaraj
Modeling Electrical Discharge Machining Process using Artificial Neural
Network for the Machining of Special Steel WP7V
Ranjan Kumar Ghadai, Rashmi Ranjan Behera and Subash Chandra
Mondal
Experimental Investigation on Near-dry Electric Discharge Machining
Krishnakant Dhakar and Akshay Dvivedi
Preliminary Investigation into Finishing of Artificial Dental Crown
Pankaj Baghel, Shreyansh Singh, Nikita Dua, V.K.Jain and Leeladhar
Nagdeve
Finite Element Modeling for Prediction of Cutting Forces during Micro
Turning of Titanium Alloy
T. Jagadesh and G. L. Samuel
Parametric Studies of Abrasive Water Jet Cutting on Surface Roughness
of Silicon Nitride Materials
Debasish Ghosh, Probal K. Das and B.Doloi
Empirical Modelling of MRR in Electrochemical-Mechanical Finishing
of Bevel gears
J. P. Misra, P. K. Jain, D. K. Dwivedi and N. K. Mehta
Effect of Layer Thickness in Micro Electric Discharge Milling: An
Experimental Investigation
J.M. Jafferson, P. Hariharan and J. Ram Kumar
Modeling and Analysis of Micro WEDM Process on Inconel Super Alloy
through Response Surface Methodology
P. Sivaprakasam, P. Hariharan and S. Gowri
Experimental Investigation of the Process Parameters in Abrasive
Waterjet Cutting of Redmud Reinforced Banana/Polyester Hybrid
Composites
M.Uthayakumar V.Arumugaprabu and M. Kathiresan
Investigation of ED-milled Tapered Channels for Microfluidic Devices
Pranit Deshmukh, Saurabh Annadate and G.Karthikeyan
Dynamic Stability of High Speed Micromilling Based on Modal Analysis
for Determining Tool-tip Dynamics
Kundan Singh, V. Kartik and Ramesh Singh
Optimization of Multiple Performance Characteristics of the Electrical
Discharge Machining Process on Metal Matrix Composite (Al/5%TiCp)
using Grey Relational Analysis
V. Chittaranjan Das and N. V. V. S. Sudheer
Application of AbrasiveWater Jet Machining in FabricatingMicro Tools
for EDM for Producing Array of Square Holes
Vijay Kumar Pal and S.K. Choudhury
Application of Pure Water Jet Machining for Improving Surface Finish of
Parts Fabricated by Abrasive Water Jet Machining
Vijay Kumar Pal and S.K. Choudhury
223.
224.
O0537
O0540
225.
O0559
226.
O0561
227.
228.
229.
230.
231.
232.
O0562
O0564
O0602
O0615
O0618
O0630
233.
O0637
234.
O0643
235.
236.
237.
O0661
O0702
O0704
238.
O0809
239.
240.
241.
O0820
O0822
O0823
Estimation of Machining Performances of P-20 Material in Wire Electric
Discharge Machining using Group Method Data Handling Technique
G. Ugrasen,H. V. Ravindra and G. V. Naveen Prakash
Parametric Analysis of Electrochemical Discharge Micro-Machining
Process during Profile Generation on Glass
B. Mallick, M.N. Ali, B. R.Sarkar, B. Doloi and B. Bhattacharyya
Modeling and Analysis of Cutting Forces in Micro End Milling
Tej Pratap and Karali Patra
Parametric analysis of CNC EDM Process on OHNS Tool Steel
K.Saraswathamma and Madhu Durgam
Comparison of Process Mechanics in µEDM-drilling and RµEDM based
on Online Monitoring of Discharge Gap Condition
C.K. Nirala and P. Saha
Development and Experimental Investigation of Electro-Discharge
Diamond Face Grinding
Sanjay Singh, Vinod Yadava and Ram Singar Yadav
Machinability Assessment of Superni-800 during EDM with Powder
Metallurgy Processed Cu-Ti Electrode Using the Taguchi Method
Vijay Kumar Bhanot, Naveen Beri and Anil Kumar
Comparative Evaluation of Mechanically Alloyed and Sintered Magnetic
Abrasives for Fine Finishing
Sehijpal Singh, Parmjit singh and H.S Shan
Abrasive Flow Finishing Process - A Case Study
T. S. Kavithaa, N. Balashanmugam and P. V. Shashi Kumar
An Experimental Investigation during Nano Finishing of Hybrid
Al/(Al2O3+ZrO2)MMC on Developed ECG Setup
Alakesh Manna and K.Z. Molla
Ultra High Finishing of Oval Bores Using Elastic Abrasive Balls
V.S. Sooraj and V. Radhakrishnan
An Experimental Investigation During Micro Drilling of Hybrid
Al/(Al2O3p+SiCp+Cp)-MMC on Developed ECMM Setup .
C. S. Kalra, Alakesh Manna and V. K. Singla
Multi Response Optimization of Ultrasonic Machining Parameters using
Weighted Principal Component Analysis
Nitesh Dhar Badgayan and P.S.Rama Sreekanth
Analysis of Parametric Effects on Response Characteristics and Faults
Diagnosis during WEDM of Al/SiCp-MMCs
Harmesh Kumar, Alakesh Manna and Rajesh Kumar
Improved Cooling unit with Automatic Temperature Controller for
Enhancing the Life of Ice Bonded Abrasive Polishing Tool
S. Rambabu and N. Ramesh Babu
Modeling and Optimization for Drilling of High Aspect Ratio Blind
Micro Holes in Micro EDM
Swapan Barman, Koustov Mondol, Nagahanumaiah and Asit Baran
Puri
Developing Alternative Polymer Abrasive Gels For Abrasive Flow
Finishing Process
Harlal Singh Mali and Jaikishan
Modelling and Prediction of Material Removal Rate in Electrical
Discharge Diamond Surface Grinding Process of Inconel-718
Harlal S. Mali, Deepak Unaune and Sandeep Tiwari
Chemo-Ultrasonic Assisted Magnetic Abrasive Finishing: Experimental
Investigations
Nitesh Sihag, Prateek Kala and Pulak M. Pandey
242.
O0862
An investigation of Wire Electric Discharge Machining of High
temperature Titanium alloy
Mohinder Pal Garg, Ajai Jain and Gian Bhushan
Abstract on Advanced Manufacturing-II: Laser based manufacturing
243.
244.
245.
246.
247.
248.
249.
250.
251.
252.
O0022
O0030
O0032
O0037
O0052
O0224
O0229
O0233
P0242
O0255
253.
O0299
254.
O0331
255.
O0337
256.
O0361
257.
O0377
258.
O0380
259.
O0395
247-260
A Simple AnalyticalModel of Laser Bending Process
E. Aideh, U. S. Dixit and R. Echempati
Mathematical Formulation for the Development of Compound Curve
Surface by Laser Line Heating
Biplab Das and Pankaj Biswas
Effect of Process Parameters on Thermal History Of Laser Welding of
AISI-304 Stainless Steel
Rakesh Bhadra, PankajBiswa and M. Ravi Sankar
A Literature Review on CO2 Laser Welding
Rakesh Bhadra, Pankaj Biswas and M. Ravi Sankar
A 3-D Finite Element Analysis Of Transient Temperature Profile Of
Laser Welded Ti-6Al-4V Alloy
Chandan kumar, Manas Das and Pankaj Biswas
Nd:YAG Laser Micro-drilling of SiC-30BN : Experimental Study and
Process Optimization
Roy. N., Kuar. A. S., Mitra, S and Acherjee, B
Experimental Studies on Fibre Laser Micro-Machining of Ti-6Al-4V
A. Sen, B. Doloi and B.Bhattacharyya
Effect of Different Surface Coatings on Laser Forming of Mild Steel
Sheets
Sunil K. Singh, Sachin S. Gautam and Uday S. Dixit
Numerical Investigation and Statistical Analysis of Laser Bending of
Titanium Sheets
K.Paramasivan, Sandip Das, Dipten Misra and M. Sundar
Effect of Pulsed Nd:YAG Laser Parameters in Preplaced TiC Coating on
Aluminium Substrate
Chinmaya Kumar Sahoo, Jageshwar Kumar Sahu and ManojMasanta
Comparative Study of Surface Roughness Criteria During Pulsed
Nd:YAG Laser Micro-Turning of Alumina Ceramic at Laser Focused
and Defocused Conditions
G. Kibria, B. Doloi and B. Bhattacharyya
Study and Analysis of the Thermal Effect during the Excimer Laser
Ablation of Polymers with Different Gaseous Environment
James Jacob, P. Shanmugavelu ,R.Balasubramaniam and Ramesh
K.Singh
Studies on CO2 Laser Micromachining on PMMA to Fabricate Micro
Channel for Microfluidic Applications
Rishi Kant, Ankur Gupta and Shantanu Bhattacharya
Fabrication of micro lens array by excimer laser micromachining
Syed Nadeem Akhtar, Shashank Sharma and J. Ramkumar
Studies on laser-sintering of copper by direct metal laser sinteringprocess
A.R.Vinod and C.K.Srinivasa
Experimental Study on Micromachining of 304 Stainless Steel Under
Water Using Pulsed Nd:YAG Laser Beam
RasmiRanjan Behera, Mamilla Ravi Sankar, Indrajeet Kumar, Ashwini
Kumar Sharma, Alika Khare and J. Swaminathan
Improvement of Corrosion Resistance by Laser Surface Melting of 7075
Aluminum Alloy
A. C. UmamaheshwerRao, V.Vasu , S.M. Shariff and K.V. SaiSrinadh
260.
261.
262.
O0436
O0462
O0541
263.
O0619
264.
O0624
265.
O0634
266.
267.
268.
O0657
O0708
O0875
269.
O0878
Finite Element Analysis on Pulsed Laser Forming of Sheet Metal
KuntalMaji, D. K. Pratihar and A. K. Nath
Modeling and Optimization on Nd: YAG Laser Marking of Zirconia
Ceramic using RSM and ANN
Josephine Peter, B. Doloi and B. Bhattacharyya
Thermo-mechanical Modeling of Laser Cladding of CPM9V on H13
ToolSteel
Santanu Paul, Ramesh Singh and Wenyi Yan
Experimental Investigations on CO2 Laser Micro Texturing on NearTitanium Alloy (IMI 834)
M. Ravi Sankar, S. Tarun Kumar, Kishor Kumar Gajrani,
J. Swaminathan and U. S. Dixit
Finite Element Simulations of Laser Bending of Small Sized Sheets
Besufekad N. Fetne and Uday S. Dixit
Surface Alloying of Aluminum with Copper using CO2 Laser
Gutu J. Woldetinsay, Mamilla Ravi Sankar and Uday S. Dixit
Energy Based Analysis of Laser Microchanneling Process on Polymethyl-methacrylate
Shashi Prakash and Subrata Kumar
Experimental Investigation on Laser Bending of Metal Sheets Using
Parabolic Irradiations
Parag M. Bhuyan, Ravi Kant and S.N. Joshi
An Experimental Investigation on Fiber Laser Welding at Controlled
Inert Gas Atmosphere
YadaiahNirsanametla, Swarup Bag, C. P. Paul and L. M. Kukreja
Fabrication of Micro-Channels on Mild Steel Using Laser Induced
Micro-Machining
Sanasam Sunderlal Singh, Kh. Shantakumar, Alika Khare and S.N.
Joshi
Abstract on Composite Fabrication
270.
O0012
271.
272.
273.
274.
275.
276.
O0013
O0054
O0103
O0128
O0173
O0183
261-273
Effect of Double and Triple Particle Size Al2O3 Reinforcement on
Properties of Aluminium Matrix Composite Prepared by Vacuum
Moulding
Rupinder Singh, Sunpreet Singh and Kanwalpreet Sahni
Investigations for Mechanical Properties of Metal Matrix Composite
Prepared by Combining FDM, Vacuum Moulding and Stir Casting
Rupinder Singh, Sunpreet Singh and Sardar Singh
Preparation and Tribological Characterization of Linear Low Density PolyEthylene Sea Shell (LLDPE/Sea Shell) Bio Composite
GajendraMundel and M. Ravi Sankar
Sisal Fiber / Glass Fiber Hybrid Nano Composite: The Tensile and
Compressive Properties
Natarajan, N. Bharathidasan, S. Thanigaivelan and R. Suresh, P
Dynamic Mechanical and Thermal Properties of Jute Nano Fibre
Reinforced Polymer Composite
K. T. B. Padal, S. Srikiran and P. Surya Nagendra
Development and Tribological Performance of Nano SiC Particles on the
AA 2024 Hybrid Composites With The Addition of Nano Graphite
S.Vinothkumar, K. Manisekar andP.Ravindran
Thermal Buckling Of Temperature Dependent Functionally Graded
Cylindrical Panel
V. R. Kar and S. K. Panda
277.
278.
279.
O0203
O0245
O0256
280.
O0289
281.
O0298
282.
O0315
283.
O0344
284.
O0345
285.
O0429
286.
287.
288.
289.
O0481
O0550
O0625
O0801
290.
O0828
291.
O0832
Fabrication and study on mechanical and tribological properties of Nano
Al2O3 and micro B4C Particles -reinforced A356 hybrid composite
Sukesha V, Rajeev Ranjan , G Nagesh and K. Sekar
Hysteresis Heating of Polypropylene Based Composites
Ravi Shukla, JohnneyMertens and S Senthilvelan
Frictional Heat Generation in Selective Ceramic Reinforced Polymer
Composites - Effect of Particle Size
C. Gurunathan, R. Gnanamoorthy and S. Jayavel
Mechanical Behaviour of Jute Fiber Reinforced Polypropylene Composites
Temesgen Berhanu, Pradeep Kumar and Inderdeep Singh
An Experimental Investigation on Polymeric Nanocomposite Material
Panneerselvam K and Jafrey Daniel James D
Tribological Performance of Microwave Sintered Copper-CNT
Composites
Rajkumar.K and Aravindan.S
Influence of Nano-Al2O3 and Micro-ZrO2 Particles on Mechanical
Property of A356 Based Composite Fabricated by Combination Effect of
Stir and Squeeze Casting
Rajeev Ranjan , Sukesha v , G.Nagesh and K Sekar
Parametric Optimization of Al-SiC12% Metal Matrix Composite
Machining by Electrical Discharge Machine
Rajesh Kumar Bhuyan, B.C. Routara, Arun Kumar Parida and
A.K.Sahoo
Development and Characterization of Functionally Graded Materials
Using Hybrid Layered Manufacturing
Sajan Kapil, Pravin M. Kulkarni, K.P.Karunakaran and Prathmesh
Joshi
Processing and Tensile Strength of 2024 Al Matrix Composite
Reinforced with Al2O3 Nano-Particles
Kapil Kumar, Dherendra Verma and Sudhir Kumar
Synthesis and machinability studies of A356 alloy-15% SiC composite
K.Jayakumar, Jose Mathewand M. A. Joseph
An Experimental Investigation on Designed and FabricatedWECSM Setup
during Micro Slicing of E-Glass Fiber Epoxy Composite
Alakesh Manna and Anup Malik
A Comparison Study of Filament Wound Composite Cylindrical Shell
used in Under Water Vehicle Application by Finite Element Method
AbhijitDey, K.M. Pandey and P.L. Choudhury
A Study on Evaluation Of Mechanical and Thermal Properties of Rice
Husk Filled Epoxy Composites
Arun Kumar Rout, Alok Satapathy, Ashok Kumar Sahoo and Dipak
Kumar Jesti
Application of Grey Fuzzy Logic for Simultaneous Optimization of
Surface Roughness and MRR in Turning Al-SiCp Metal Matrix
Composites
Santosh Tamang and M. Chandrasekaran
Abstract on Rapid Prototyping
292.
293.
O0123
O0171
275-279
Machine Element Reconstruction Using Integrated Reverse Engineering
and Rapid Prototyping Approach
Atul Kumar, P.K. Jain and P.M. Pathak
Study and Analysis of Metallized electrode fabricated with FDM Rapid
Prototyping Technique for Electro Discharge Machining (EDM)
Savan D. Fefar and Jayant S. Karajagikar
294.
O0189
295.
O0246
296.
297.
O0399
O0468
Physical Replication of Human Bone using Direct integration of Reverse
Engineering and Rapid Prototyping Techniques
N. N. Kumbhar, A. V. Mulay and B. B. Ahuja
Integrated AHP and TOPSIS Approach For the Selection of a Rapid
Prototyping Process under Multi-Criteria Perspective
Biranchi Narayan Panda, Bibhuti Bhusan Biswal, and B. B. L. V.
Deepak
Intelligent Performance Modeling and Optimization in Rapid
Manufacturing
Ushasta Aich, Amar M. Phatak and S.S. Pande
Location Dependency of Positioning Error in 3-Axes CNC Milling
Machine
R.K. Gupta, S.P. Srivastava, S.K.Yadav, V. Prasad and S.B. Jawale
Abstract on Metrology
298.
O0060
299.
O0386
300.
O0632
301.
O0810
302.
O0874
Comparison of Servo Tracking Capability of the Interconnected Cylinders
Positioning System with Servo Pneumatic Positioning System
D. Saravanakumar and B. Mohan
Recent Advances in Burr Height Minimization in Micro-Machining
Muddu Allaparthi and Mohammed Rajik Khan
Predication of Surface Roughness of Freeform Surfaces using Artificial
Neural Network
Rajesh M. and R Manu
Blind Assembly Using Digital Metrology for Satellite Applications
C. Koteshwara Rao, Rohit Jain, Pravesh Mathur and K. V.Govinda
Study of Profile Changes in Magneto-Rheological Abrasive Honing by an
Ingenious Relocation Technique
ChidambaraKumaran and M.S. Shunmugam
Abstract on Material Science
303.
304.
305.
306.
307.
308.
309.
310.
O0055
O0110
O0141
O0190
O0263
O0396
O0471
O0522
281-284
285-294
Experimental Investigations of Ni/La2O3 Composite Micro-Cladding on
AISI 1040 Steel through Microwave Irradiation
Arbind Prasad, Dheeraj Gupta, M. Ravi Sankar and A. Naryana Reddy
Some Chemo-Rheological Studies of
Aqueous Silicon Nitride
Suspensions in Gelcasting process
T. Nagaveni, K. Kishore Kumar and C. S. P. Rao
Characterization and Optimization of ElectrospunPolyacrylonitrile (PAN)
and Polyvinylidene Fluoride (PDVF) Nanofibers
R. Ankit Chaudhary and B. B. Ahuja
Surface Modification of Aluminum by Electrical Discharge Coating with
Tungsten and Copper Mixed Powder Green Compact Electrodes
D. Tijo and Manoj Masanta
Transverse Rupture Strength of Solid Lubricant Cutting Tool Material
A. Muthuraja and S. Senthilvelan
Concurrent Evaluation of Electroplating Effluent Treatment System for
‘X’- Abilities Using Graph Theory and MADM Method
Abhishek Kumar, Shibu Clement and V.P. Agrawal
Effect of Microstructure with Hardness on Heat Treatment of HP40Nb
Microalloyed Reformer Tube
Amitava Ghatak and P.S.Robi
Numerical Modelling of Impact and Solidification of a MoltenAlloy
Droplet on a Substrate
Rajesh Kumar Shukla, Sateesh Kumar Yadav and Mihir HemantShete
311.
O0560
312.
O0609
313.
O0610
314.
O0622
315.
316.
317.
318.
319.
O0645
O0696
O0815
O0844
O0858
and Arvind Kumar
Enhancement of Mechanical Properties of Recycled Green Sand by
Addition of Alumina
A.K. Birru, L. Dharam Singh and P. Arun Kumar
Size Effect on Mechanical Behavior of SS304
Jambeswar Sahu and Sushil Mishra
Accumulative Roll Bonding of AA6005 and AA1060 Metal Strip: Study
on Microstructure, Mechanical Properties and Evaluation of Minimum
Bonding Criteria
SuprimSardar, Atanu Mandal , Surjya Kanta Pal and Shiv Brat Singh
Influence of Rolling and Age-Hardening on the Hardness and Impact
Properties of Microalloyed 2219 Al Alloys
Sanjib Banerjee, GourabJyoti Bayan, Achyut Roy, Saurav Sarkar and
Debajit Gogoi
Study of Structural Materials for Machine Tools
N.Mahendrakumar, S. Syth Abuthakeer and P. V. Mohanram.
Nucleation and Growth of Diamond by Different Seeding Mechanisms on
Cemented Carbide Inserts by HFCVD Process
S. K. Sarangia, D. K. Sahub, S. Padhic and A. K. Chattopadhyayd
Nano Red Mud – Synthesis and Characterization
C. Neelima Devi, N. Selvaraj and V. Mahesh
Fabrication of Array of Gold Nanoparticles through Thermal Dewetting
and Fib Patterning
A. Goswami, S. Aravindan and P.V. Rao
Simulation Of Fluidity Inaluminum Alloys, Superalloy CMSX4, And
Ductile Cast Iron
D. Mohan Krishna and G. S. Reddy
Abstract on Design
320.
321.
322.
323.
324.
325.
326.
327.
328.
O0071
O0105
O0196
O0207
O0238
O0305
O0321
O0355
O0465
295-304
Micro Manipulation by a Compliant Piezoelectric Micro Gripper towards
Robotic Micro Assembly
R. K. Jain, S. Majumder and Bhaskar Ghosh and Surajit Saha
Hybrid Neural Network Based Prediction of Inverse Kinematics of Robot
Manipulator
Panchanand Jha and, B. B. Biswal
Vibration Analysis of a Cutting Tool with Piezoelectric Bimorph
A. Garg and S. K. Dwivedy
Thermal Stress and Creep Analysis of Failed Tube of Secondary Super
Heater
Amit N. Parit, Tadamalle A. P and Vasantha Ramaswamy
Hybrid edge detection technique for part identification in robotic
assembly system under vision guidance
Bunil Kumar Balabantaray and BibhutiBhusan Biswal
Constraint and Inverse Kinematic Analysis of 3-PRS Parallel
Manipulator
Yashavant Patel and P. M. George.
Fabrication and Pose Control of 2T2R-Based Parallel Manipulator for
Drilling Operations
P.K Binyam and A.P Sudheer
Fabrication and Control of Vision Based Wall Mounted Robotic Arm for
Pose Identification and Manipulation
R. Induraj and A.P Sudheer
Design of Multimode Microwave Cavity for Materials Processing
Dharmendra Singh Rajpurohit and Rahul Chhibber
329.
330.
331.
332.
333.
334.
335.
336.
337.
O0565
O0572
O0651
O0666
O0670
O0687
O0707
O0838
O0859
Studies on Green Design & Manufacture of Hybrid Vehicle
P.P. Dutta, D. Das, M.Dutta, A.M. Shukla, T.K. Gogoi and A. Das
Development of an Efficient Hybrid Tricycle
P.P. Dutta, S. Sharma, A. Mahanta S. Gupta, A. Choudhury, K.
Barman, D. Barua, R. Gogoi and A. Das
Design and Development of Automated Vegetable Cutting Machine
A. Tony Thomas, A. Muthu Krishnan and K.S. Sre Nandha Guhan
Inverse Kinematic Modeling of a 6-DOF(6-CRS) Parallel Spatial
Manipulator
Yogesh Singh and Santhakumar Mohan
Design and Analysis of a Single–Notch Parallelogram Flexure
Mechanism Based X-Y Nanopositioning Stage
S. N.Vithun, T. Narendra Reddy, Prakash Vinod and P. V. Shashikumar
More Special Cases in Specifying the Deviation of3D Reference Axes
T. S. R. Murthy and T. Shravan Kumar
Investigation and Analysis of Chatter Vibration in Centerless Bar
Turning Machine
M. Girish Kumar, Prakash Vinod and P.V. Shashikumar
Multiple Objective Based Machine-Part Cell Design Considering Ordinal
and Ratio Data Through NSGA II
Iti Dixit, Saurabh Jain and Kapil Kumar Goyal
Design and Analysis of Vertical Dynamic balancing machine flexure for
satellite balancing
Rajeev Chaturvedi, Shree Niwas Sahu, A. Sekar and K.V .Govinda
Abstract on Tribology
338.
339.
340.
O0117
O0416
O0554
Evaluation of Wear Behavior of a Nonmetallic Spur Gear
Jagannath Sardar and Dibakar Bandopadhya
Investigation of Tribological Characteristics of Non Edible Castor and
Mahua Oils as Bio Lubricant for Maintenance Applications
Amit Kumar Jain and Amit Suhane
On Improvement of Tribological Performance of Pulsed DC CFUBM
Sputtered WS2 Solid Lubricant Coating Through Addition of Ti or TiN
Tushar Banerjee and A. K. Chattopadhyay
Abstract on Industrial Engineering & Operations Research
341.
342.
343.
O0011
O0021
O0036
344.
O0057
345.
346.
O0061
O0062
305-308
309-335
Design and Development of Automated Test System for Aircraft
Hydraulic Control Module at Assembly and Manufacturing Floor
Karthik SP,Vijay Desai and KantilalL Hirani
Material Handling Equipment Selection by Fuzzy Axiomatic Design
Principles
Anant V. Khandekar and Shankar Chakraborty
Application of Process Capability Indices to Measure Performanceof a
Multistage Manufacturing Process
S. C. Mondal and S.Kundu
Design and Development of Feature Extraction and Recognition
Information System for Computer Aided Process Planning Systems
Sreenivasulu Reddy, A., Poornachandra Sekhar,Y., Rajendra Prasad,T.
and Ravindranath,K.
SMED (Single-Minute Exchange of Die) Methodology in Garment
Manufacturing Industry: Case Study in Reducing Style Change Over Time
Jonalee Das Bajpai
Prediction of Life of Punches of Compound Die using Artificial Neural
347.
348.
349.
350.
351.
352.
353.
354.
355.
356.
357.
358.
359.
360.
361.
362.
363.
364.
O0069
O0072
O0106
O0126
O0138
O0139
O0169
O0201
O0209
O0214
O0216
O0320
O0324
O0352
O0384
O0406
O0418
O0419
Network
Sachin Kashid and S. Kumar
Integrated Decision Making in Supply Chain Management and Its
Relevance to Industrial Practice
Amandeep Singh and Sandeep Singhal
Impact of Reconfiguration Effort on Reconfigurable Manufacturing
System
K. K. Mitta and P. K. Jain
Application of Grey based Decision Making Approach for Lean Tool
Selection
Adarsh Kumar Singh, S. Vinodh and K. E. K. Vimal
A Green Process Planning System
M. Gogoi and M. Hazarika
Application of Remanufacturing Principles to an Automotive Engine
Valve Component
K. J. Manjunatheshwara, S. Vinodh and K. E. K. Vimal
Application of S-LCA methodology for assessment of automobile
organization
K. E. K. Vimal and S. Vinodh
A Novel Cell Formation Technique in Cellular Manufacturing System
Based on Various Production Factors
Tamal Ghosh, B. Doloi and Pranab K. Dan
A comparative study on the reflectivity of metallic mirrors finished by
deterministic and random processes
Anuj Sharma , Prabhat Ranjan, D. Datta and R. Balasubramaniam
Identification of Pressures, Barriers and Drivers for the implementation of
Green Supply Chain Management
M. Deepak, A. Noorul Haq and K. Mathiyazhagan
A New Hybrid Approach to Recognize Machinable Features of Prismatic
Parts from STEP AP 203 File
Bitla Venu, Venkateswara Rao Komma and Deepanshu Srivastava
STEP-Based Feature Recognition of Orthogonal Primitives of Prismatic
Parts
Deepanshu Srivastava, Venkateswara Rao Komma and Bitla Venu
Supply Chain Complexity: Challenges and Future Research directions
E.G Kavilal, S. Prasanna venkatesan and K.Dadhaniya Harsh kumar
An Assessment of Sustainable Supply Chain using MCDM
K. Sivakumar, R. Jeyapaul and P. Parthiban
Optimization of Flexible Flow Shop Scheduling with Sequence Dependent
Setup Time and Lot Splitting
Vinit Saluja and Ajai Jain
Scheduling a Stochastic Dynamic Job Shop Manufacturing System with
Sequence-Dependent Setup Times
Pankaj Sharma and Ajai Jain
Improvement of Agile Software Production Management Using System
Dynamics Model
Pijush Chandra Das and U. R. Dhar
Risk Mitigation in Manufacturing Process Through Development of 4M
Model
S. Kumar and P. Sharma
Knowledge Transfer, Process Fit and Other Issues in ERP Implementation
in an Indian SME
Sanjay Kumar
365.
366.
367.
368.
369.
370.
371.
372.
373.
374.
375.
376.
377.
378.
379.
380.
381.
382.
383.
O0445
O0463
O0467
O0474
O0482
O0517
O0527
O0532
O0534
O0542
O0547
P0552
O0567
O0568
O0570
O0584
O0585
O0620
O0635
A Case Study of Six Sigma and its Competitive Advantage in Indian
Industries
Parvesh Kumar, Sandeep Singhal and Jimmy Kansal
Application of Lean Principles to Reduce the Non-value Adding
Transportation Activities in a Rubber Components Manufacturing industry
K. Balaji and V.S.Senthil Kumar
Integrating Quality Aspects in Design and Manufacturing of Optical
Alignment System
R.K. Gupta, S.P. Srivastava, S.K.Yadav and S.B. Jawale
Understanding Different Stake holders of Sustainable Product and Service
Based Systems Using Genetic Algorithm for Sustainable Manufacturing
Sameer Gupta, Prabir Sarkar and Ekta Singla
Integrated
Approach
for
Job
Scheduling
and
MultiComponentMaintenance Planning in a Production System
Sandeep Kumar, Bhushan S. Purohit and Bhupesh Kumar Lad
Perceptions of Manufacturing Industries in Adopting Third Party Logistics
Providers – An Empirical Study
Vivekanandhan Porselvan, Karthik Subramanian and Ashwin
Vijayakumar
Group Technology in Design of Manufacturing Systems- A Review
Kamal Khanna, Gazal Preet Arneja and Rakesh Kumar
Improved Music Based Harmony Search Algorithm (IMBHSA) for
solving Job Shop Scheduling Problems (JSSPs)
M. Hymavathi and C.S.P Rao
Development of New Paradigms for Job Shop Scheduling Problems
M. Hymavathi and C.S.P Rao
System Dynamics Model in the Analysis of Manufacturing Defects and
Process Improvements
B. Chowdhury, S.K. Deb and P.C. Das
Development of SPM for Automation in Sheet-Metal Disc TeethCutting
Operation
Chetan Mahatme, Sachin Mahakalkar and Jayant Giri
Productivity Improvement through Modular Line in Garment Industries
B.Sudarshan and D. Nageswara Rao
Status of Implementation of Lean Manufacturing Principles in the Context
of Indian industry: A Literature Review
A. P. Chaple, B. E. Narkhede and M. M. Akarte
Tool Inventory Management using RFID Technology
Ishwar Bhiradi and Ajesh J.Pillai
Work Measurement Approach for Productivity Improvement in a Heavy
Machine Shop
Ishwar Bhiradi and B.K.Singh
Single Model Assembly Line Balancing for Newly Recruited Employees
Sandeep Choudhary and Sunil Agrawal
Decision Making using Analytical Hierarchical Process (Ahp) for
Selection of Best Suitable Maintenance Method for Multispindle Automat
AS32
Jayant S. Karajagika and, B.U.Sonawane
Comparative Analysis of Manufacturing System Using Cause – Effect
Diagram and System Dynamic Model
B.Chowdhury and S.K. Deb
Optimization of Machining Time using Feature based ProcessPlanning
B. R. Borkar, Y. M. Puri, A. M. Kuthe and P. S. Deshpande
384.
385.
386.
387.
388.
389.
390.
391.
392.
393.
O0640
O0641
O0642
P0644
O0646
O0649
O0659
O0683
O0812
O0825
394.
O0837
395.
O0873
“TPM-A PDCA Approach”
P.K.Suresh, Dr. Mary Joseph and Dr.Jagathy Raj.V.P
Mixed-Model Assembly Line Balancing Problem: A Focus on
ModelFormulation
U-line Assembly Balancing for Medium Commercial Vehicle Eicher
Motors Ltd: A Case Study
Implementation of Six-Sigma Methodology for Improvement of Process
Yield by Reduction of Rejection (for %) in a Manufacturing Process
S. Chandra, B. Doloi and B.K. Bhattacharya
Safety Management in Manufacturing Industry: A Lean Six Sigma
Approach
P. R. Gajbhiye , A. C. Waghmare, and R. H. Parikh
Root Cause Analysis of Tong Mark defect During Material Handling of IF
Steel Coils
G.Mathan, G.Manikandan and M. B. N. Raju
Parametric Optimization of Machining Parameters Using Graph Theory
and Matrix Approach
L. B. Abhang and M .Hameedullah
Automatic Identification of Cylindrical/Tapered Features from Prismatic
Components
Dowluru Sreeramulu, A. Satish Kumar and C.S.P.Rao
Comparative Assessment of Primitive Features Machined with Different
Diameter End Mill Tools Using Reverse Engineering Technique
Sachin Gupta and A. A. Shaikh
Systematically Investigating Literature of Supply Chain Risk
Management: A Review for Risk Prioritisation
Surya Prakash, Sameer Mittal, Gunjan Soni and Ajay Pal Singh Rathore
Aero-Engine Compressor Development Through Reengineering based
Product Development Cycle
S. N. Mistry, Amar Singh and K. Joseph Shibu
Enhancing Agility of Supply Chains using Stochastic, Discrete Event and
Physical Simulation Models
Alok K. Verma
Abstract on Miscellaneous Papers
396.
397.
398.
399.
400.
401.
O0008
O0046
O0056
O0058
O0098
O0118
337-351
Manufacturing Experiences of a High precision Six Axis Parallel
Manipulator (Hexapod)
R. K Sachan, J.J. Roy, H.B Panse and S.B. Jawale
Theoretical and Experimental Verification of Vibration Characteristics of
Cracked Rotor System in Viscous Medium
Adik R. Yadao and D.R.Parhi
Performance based Optimal Machine Assignment in Reconfigurable
Manufacturing System using Genetic Algorithm
Faisal Hasan, P.K.Jain and Dinesh Kumar
Experimental investigation of cereal crop drying in an inclined Bubbling
Fluidized Bed
Phyu Phyu Thant, P.S.Robi and P.Mahanta
Formulating Midsurface using Shape Transformations of Form Features
Yogesh H. Kulkarni, Anil Sahasrabudhe and Mukund Kale
Grade Mixing Analysis in Steelmaking Tundish using Different
Turbulence Models
402.
403.
404.
O0278
O0292
O0304
405.
O0362
406.
407.
408.
409.
410.
O0366
O0389
O0417
O0439
O0450
411.
O0458
412.
O0489
413.
414.
415.
O0494
O0555
O0557
416.
O0578
417.
O0590
418.
419.
O0607
O0623
Md. Irfanul Haque Siddiqui and Pradeep Kumar Jha
Degraded Performance Analysis of Phased Mission System
M.D.Jaybhaye , Manmohan Singh and S.K.Basu
Development of Low Cost Deburring Setup with Feedback Capability
S. T. Bagde and A. V. Kale
Effect of Hydraulic Accumulator on the System Parameters of an Open
Loop Transmission System
M. K. Barnwal, N. Kumar, Ajit Kumar and J. Das
Engineering of Micro Patterned Surface Topographies – Correlating
Pattern Geometry and Bacterial Resistance
Aneissha Chebolu, Bhakti Laha, Monidipa Ghosh, and
Nagahanumaiah
An Efficient Manufacturing Simulation Model for Doubly Curved
Structures in Shipbuilding
K. Thomas, R. Sharma and S. K. Bhattacharyya
Effect of the Cryogenic cooling on Surface Quality of Ground AISI
52100 Steel
P. Prudvi Reddy and A.Ghosh
Behavior of Thermally Sprayed Bioceramic Coatings after immersion in
SBF: A Review
Amardeep Singh, Gurbhinder Singh and Vikas Chawla
A Study of Electroplating Process through Experiment and Simulation
Abhijeet Selhi and Sai Nikhil
A Perspective Analysis on Emergence of Renewable Energy Basis
Technology to Industrial Development in Bangladesh: Prospect,
Overview and Fate of the Environment
Rakhee Mondal, Deeponker Sarkar and Debashis saha
Porosity Reduction in Laser Sintered Specimen Made of Tungsten
Carbide and Cobalt Powder
Subrata Kumar Ghosh, Alok Kumar Das, Sojiram Meena and Partha
Saha
Investigation of Different Combustion Chamber Geometry of Diesel
Engine Using CFD Modelling of In-Cylinder Flow for Improving the
Performance of Engine.
A.M. Indrodia, N.J. Chotai and B.M.Ramani
Prediction of Remaining Useful Life of an Aircraft Engine under
Unknown Initial Wear
Amit Kumar Jain, Pradeep Kundu and Bhupesh Kumar Lad
Vibration Analysis of Variable Compression Ratio Engine Using Virtual
Instrumentation
Abhishek singh, H. chelladurai and Akhilesh kumar chaudhary
Condition Monitoring of Rotating Shaft Using Virtual Instrumentation
Ajay choubey, H. Chelladurai and Subir Singh Lamba
Mathematical Modeling of Wave Propagation in Elastic Solids
Srinivasa Rao and Janakiram Perumalla
Design and Development of Manually Operated Seed Planter Machine
A. R Kyada and D. B Patel
Simple Fabrication of PDMS Based Microfluidic System for Mixing and
Detection System
Khalid Anwar, Sandip S Deshmukh and Sun Min Kim
Automatic Feature Recognition of Cylinder and Knuckle Thread from
Neutral Files
M.M.M.Sarcar, P.Madar Valli and V.Naga Malleswari
420.
421.
O0689
O0705
422.
O0706
423.
O0869
Optimizing Preload and Coefficient of Friction for Surface Acoustic
Wave Linear Motor
Basudeba Behera and Harshal B. Nemade
Parametric Studies on Side Impact Beam Tube
Rajesh Male, Ashwin Karthikeyan and Krishna Srinivas
Analysis of Optimal Methodology for Geometry Reconstruction of An
Airborne Launcher
Kushal Singh, L. Siva Rama Krishna, B. Hari Prasad and P.
Bhattacharjee
Analysis of the Novel Brake Rotor using FEM
A.K.Matta and V.Purushottam
A brief biography of our chief guest Prof. Amitabha Ghosh
Amitabha Ghosh was born on 3rd December, 1941 at village Barhra of Birbhum district, West Bengal. After
completing his high school education at the village school in 1956 and Intermediate Science from Suri
Vidyasagar College (under Calcutta University) in 1958 he received his Bachelor of Engineering and Master of
Engineering degrees from Bengal Engineering College, Shibpur, (Calcutta University) in 1962 and 1964,
respectively. He joined the Mechanical Engineering Department of this college as a Lecturer in 1965 May and
continued his doctoral research finally receiving the Doctorate degree from Calcutta University in 1969. He
joined IIT Kanpur in January 1971 as an Assistant Professor of Mechanical Engineering and became Professor
in 1975 June at the age of 33 & 1/2 years. From 1977 to 1978 he spent at the Technical University Aachen
with Alexander von Humboldt Foundation Senior Fellowship. From 1997 to 2002, he served IIT Kharagpur as
the Director and subsequently returned to his Professorial position at Kanpur where he continued up to 2006
till his retirement. Currently he is a Senior Scientist of the Indian National Science Academy, New Delhi and
Honorary Distinguished Professor at IIT Kanpur and Bengal Engineering & Science University, Shibpur.
ACADEMIC AND RESEARCH CONTRIBUTIONS: Prof. Ghosh started his research activities at BE
College and guided a number of Masters’ students in the areas of Manufacturing Science and Mechanism &
Machine Dynamics. He, along with his students, discovered a new tribological effect when magnetic fields are
imposed on ferromagnetic bodies. He also discovered the means of enhancing vibration damping through
introduced stress concentration in structural members. At IIT Kanpur he guided a large number of Masters’
and 19 PhD students. He, along with his students, was the first to discover the phenomenon of chaos in
mechanical systems and conducted the first experiments on mechanical chaos in 1978. He was the first to
develop a method to analyze the kineto-elasto-dynamic problems of high speed mechanisms which was used in
many subsequent design problems by the researchers in machine dynamics. He proposed a new gravitational
theory based upon the model of inertial induction and Mach’s Principle that lead to a number of profound
cosmological and astrophysical consequences. Besides developing some new manufacturing processes
utilizing the electrochemical discharge phenomenon and some new stationary and mobile robotic systems for
the Department of Atomic Energy, Prof. Ghosh also developed an innovative regenerative brake mechanism
and stable drive system for cycle rickshaws. He invented a number of new drive systems and mechanisms
which found very effective use in advanced mechanical systems. He published over 120 journal research
papers and written five books; the textbooks by him made a lasting impression on the way the subjects are
taught now in India and abroad.
OTHER CONTRIBUTIONS: Professor Ghosh served IIT Kanpur as the Head of Mechanical Engineering
and also as the Principal Coordinator of the Quality Improve Programme of the MHRD. He initiated the first
academic programme in Robotics in India in 1984 and the first Centre for Robotics was set up at IIT Kanpur
with him as the founder Head. At IIT Kharagpur he started the first Master’s programme in Medical Science
and Technology for MBBS doctors in India; he also started the Centre for Theoretical Studies, Centre for
Advanced Technology, Space Technology Centre, the School of Medical Science & Technology, the School of
Information Technology and the Media Lab Asia at IIT Kharagpur. During his tenure an Extension Centre of
the Institute was established at Bhubaneswar and Post Graduate Diploma programmes were started at Kolkata
and Bhubaneswar Centres. The Institute underwent a very major transformation both from academic and
infrastructural points of view during his tenure. He was the Indian Coordinator for the India-Japan Science
Collaboration programme on Advanced Manufacturing from 1998 to 2005. He coordinated Indo-Us Centre for
Research Excellence on Fabrionics, funded by the Indo-US Science & Technology Forum, for collaborative
research in advanced and futuristic manufacturing involving IIT Kanpur, IIT Kharagpur, Bengal Engineering
& Science University, CMERI Durgapur, University of Illinois at Urbana Champaign, Northwestern
University Evanston, University of Illinois Chicago, University of California Irvine and University of Missouri
Columbia. The Centre activities have already led to the development of a number of cutting edge technologies.
As the Chairman of the Research Council of Central Mechanical Engineering Research Institute, Durgapur he
has helped the Institute in transforming itself into an advanced research centre in a number of emerging areas.
He was the Chairman of the DST’s FIST programme for Engineering Sciences for 6 years and was also the
Chairman of the CSIR Engineering Science programme.
AWARDS: Professor Ghosh received the Calcutta University Gold Medal for standing First Class First in the
Bachelors’ and Maters’ examinations. He also received the Calcutta University A H Pandya Endowment Gold
Medal for standing first among the students of all the branches of engineering. He was the first to receive the
Distinguished Teacher Award of IIT Kanpur, National Design and Research Award by the Institution of
Engineers (India), and the lifetime Achievement Award at the International Manufacturing Design &
Technology Research Conference. He is a Fellow of the institution of Engineers (India), Indian National
Academy of Engineering, New Delhi, Indian Academy of Sciences, Bangalore, Indian National Science
Academy, New Delhi and the National Academy of Sciences, India, Allahabad. He was also made an
Honorary Life Fellow of the Association of Mechanisms and Machines. He served INSA in the Sectional
Committee for Engineering from 2001-2003 and from 2007 till date. He has been conferred with Doctor of
Science (honoris causa) by Bengal Engineering and Science University, Shibpur.
EXTRACURRICULAR: Professor Ghosh likes to sketch and draw portraits. He is interested in classical
music and occasionally plays pakhawaj. He also writes articles in Bengali for the children which were
published in magazines like Anandamela. He also wrote articles in Desh and two of his novels have been
published by m/s Dey’s Publisher and Sahityam.
Prof. Ghosh is very active in teaching, research and mentoring the teachers. He has been visiting IIT Guwahati
frequently and helping it with his valuable suggestions. Recently, he conducted special lecture sessions on
Engineering Mechanics at IIT Guwahati. In the past also, he delivered many motivating talks at IIT Guwahati.
Receiepents of Life Time Achievment Awards of AIMTDR 2014
From Academia
From R&D Organizations
Prof. V.K. Jain
Prof. V.K. Suri
A brief biography of Prof. V.K. Jain
Dr. Vijay K. Jain passed his B. E. (Mechanical) from M.A.C.T. Bhopal (affiliated to Vikram University
Ujjain) in 1970, and M. E. (Production) from University of Roorkee in the year 1973. He did his Ph.D. from
University of Roorkee in Mechanical Engineering in the year 1980. He has more than forty years of teaching
and research experience. He has served as a Visiting Professor at the University of California at Berkeley
(USA) and University of Nebraska at Lincoln (USA). Presently he is a Professor at Indian Institute of
Technology Kanpur. He has also served as a faculty member at other Indian institutions, namely, M. R.
Engineering College Jaipur, B. I. T. S. Pilani, and M. N. R. Engineering College Allahabad.
Dr. Jain has won three gold medals, two silver medals and one best paper award ain recognition to his research
work. Recently one of his papers got Strickland Prize of the Manufacturing Industries Division of The
Institution of Mechanical Engineers (UK). The Institution of Engineers (India), Khosla Research Awards
committee and All India Manufacturing Technology Design and Research (AIMTDR) conference organizing
committee have given this honor to him. He was also conferred Vidyabharati felicitation by Hindi Prachaarini
Samiti, Kanpur.
Dr. Jain has written total seven books and more than thirteen chapters for different books published by Indian
and International publishers. Dr. Jain recently edited two ‘Micromanufacturing Processes’ (published by CRC
Press, USA) and ‘Introduction to Micromachining’ (Published by Narosa Publishers, New Delhi) text books.
He has written two books in Hindi (Slide Rule and Workshop Technology) also. Dr. Jain has edited the
proceedings of the short term schools on Precision Engineering (SERC School), Advanced Manufacturing
Technology (SERC School), Computer Integrated Manufacturing Systems, and Numerical Control Machine
Tools and Advanced Machining Processes.
Dr. V. K. Jain has been appointed as an Editor-in-chief for one International Journal, Full Editor of two
International Journals and Associate Editor of three International Journals. He has also worked as a GuestEditor for more than twelve special issues of different International Journals. He has been opted as a member
of the Editorial Board of more than twelve International Journals. Lately, he has been appointed as an Editor
of “Micro- / Nano-Manufacturing” series of Taylor and Francis (CRC Press), USA. He is editor of American
Biographical Institute.
Dr. Jain has organized Eighteen summer / winter/ short term schools on various topics such as
‘Micromanufacturing’ (three times), ‘Micromachining’ (four times), ‘Advanced Machining Techniques’ (three
times), ‘Precision Engineering’, ’Computer Integrated Manufacturing Systems’, ‘Design of Machine Tools’,
‘N. C. Machine Tools’ (two times), ‘Advanced Manufacturing Technology’, ‘Tools and Die Making’, and two
‘Contact Programs’ (DST sponsored) for undergraduate students.
Dr. Jain has eleven Indian patents and one USA patent to his credit. Based on these patents, BARC Mumbai
has developed a CMMRAFF machine for their in-house uses, and CMTI has developed AFF machine for
finishing different kinds of work pieces. HAL Kanpur also has been able to know the technology for nanofinishing of their helicopter bearings which they get them done from outside India.
Dr. Jain has operated twenty three sponsored research projects (costing approx. three crores and twenty five
Lakhs) by different agencies in India. Dr. Jain also brought seven consultancy projects (approx. Forty Lakhs
only) from private and public undertakings.
Dr. Jain has guided Fifteen Ph.D. theses. He has also guided eighty eight M. Tech. / M. E. theses, 9 M.E.
Projects and more than thirty B. Tech. / B.E. Projects while working at different Universities / Institutions
during his carrier. He has around 305 publications to his credit. He has published about 183 research papers
in referred Journals, 107 in conference proceedings, 11 in popular magazines. He has delivered more than
twenty six keynote lectures in different conferences / workshops / Universities.
Dr. Jain has been opted as Vice-President of the National Advisory Committee of AIMTDR, India
consecutively for two terms (Four Years). He has served / is serving as a member of national committees like
PAC of International programs of Materials and Engineering Science, R & D Lab. accreditation committee
(DST), Program Advisory committee (DST, PAC-(R & M)), Management Advisory Committee (DST, MAC),
National Advisory Committee for Precision Engineering, and National Advisory Committee of AIMTDR. He
has served as a Research Advisory Board of CMTI Bangalore.
Dr. Jain has served as Adjunct Faculty of Maharana Pratap Univ. of Agriculture and Technology, Udaipur
(Rajasthan). Presently he is Adjunct Faculty of Mangalayatan University Aligarh. He has served as a member
of Board of Governors of MMM Engineering College, Gorakhpur. He has also served as Member, Senate of
Indian Institute of Technology, Roorkee, MANNIT Bhopal, IIITDM Jabalpur.
Dr. Jain had been a member of different Academic bodies, namely, ASME, ASPE, and SME. At present, he is
a fellow of The Institution of Engineers (India) and Indian Society of Technical Education.At the Institute
(IITK) level, Dr. Jain has served two terms as Chairman of Commercial Establishment Monitoring &
Management Committee, Institute Gas Service Users Committee, Two terms as Chairman Health Center Users
Committee, and Two terms as Chairman Institute Assessment Committee. He has also served two terms as
Convener of DPGC, Department Space Allocation Committee, Department Funds Allocation Committee and
two times as Convener Project Evaluation Committee. He has served as a member of various Department and
Institute level committees and Warden of Hall of residence 5.
A brief biography of Dr. V.K. Suri
Dr. V. K. Suri is presently working as an outstanding scientist and Heads of Precision Engineering division
and Machine Dynamics Division. He is also the convener of DAE steering Group for Micro-Nanotechnology
and related areas. He is also a Professor in Homi Bhaba National Institute and a member of doctoral committee
of the same institute. Dr. Suri was born on 4th November 1950. He completed his graduation in Mechanical
Engineering from NIT Jaipur (erstwhile REC Jaipur) in 1973 and PhD from IIT Bombay in 1999. He joined
BARC on 1st August 1975. Prior to this, he has worked for two years at DCM, Kota, Rajasthan.
Dr. V. K. Suri has been among the pioneers and a prime contributor in the strategic project of DAE since
inception. He had incorporated several innovative ideas overcoming mechanical engineering challenges in
implementation of the strategic project. His major contribution is the development & large scale deployment of
ultra-precision high performance high-speed hydrodynamic bearings. He established unique state-of-the-art
technological facilities for indigenous development of these high speed bearings. The bearings have been
running in the plant in large numbers for over a decade, non-stop and maintenance free.
He was the Convener of ‘DAE Steering Group for Micro-Nanotechnology’. He has great outreach and
numerous collaborations. He is the visionary of ‘Micro-Nanotechnology in Service of Rural India’ and
promulgates his idea of ‘Regional Relevant Research’ in the country. He has always motivated and granted
patronage to young researchers to the level of excellence.
Dr. Suri was instructed in collaboration with leading Academic Institutes viz. IITs, BITS, IT-BHU, PSGCoimbatore, Jadavpur University. He has guided/mentored 20 M.Tech. and 5 Ph.D. students. Dr. Suri persued
Photo Chemical machining as a hobby. He used this technology for developing the spiral groove patterns after
exposure under laser. He exploited this technique for “societal’ benefits in following way:
He has conducted workshops, two in Maharashtra and one in North-East, to give hand-on training to
artisans. He inducted more than 100 artists into learning Photo Chemical Machining for:
• Preservation & Revival of Traditional Painting styles
i.e., Kalamakari, Madhubani, Phad Chitr, Pichhvai and Warli
• Employment Potential for traditional & tribal artists in rural India.
He Improvised PCM technique till the extent it can be used in rural India without electricity.
Since last few years, Dr. Suri has been working for application of advanced technology for societal
applications. Some of his work includes
• Micro Sensors for fast TB detection
• Micro Titration device for Water Testing
• Advance Raisin making technology development
• Invasive Blood pressure sensor
• Indigenous Dental Implant
• Indigenous Knee/hip Prosthesis
Dr. Suri has filed seven patents, published 5 journal papers and 30 Conference papers. He has written two book
chapters. Dr. Suri has conducted about 20 workshops in the last decade in colobration with various IITs. Dr.
Suri is a member of National Advisory Committee member of AIMTDR
Dr. Suri briefing about initative for Societal Cause during recent visit of Honourable Prime Minister to
BARC
Past AIMTDR Awardees
Life Time Achievement Awardees from Academia
AIMTDR 2000, IIT Madras: Prof. S. K. Basu
AIMTDR 2004, VIT Vellore: Prof. V. Radhakrishnan
AIMTDR 2006, IIT Roorkee: Prof. Amitabha Ghosh
AIMTDR 2008 IIT Madras: Prof. P. Radhakrishnan
AIMTDR 2010 Andhra University Visakhapatnam: Prof. A. K. De
AIMTDR 2012 Jadavpur University: (1) Prof. P. K. Mishra (2) Prof. A. B. Chattopadyay
Life Time Achievement Awardees from Industry
AIMTDR 2004, VIT Vellore: Dr. N. Ravichandran
AIMTDR 2006, IIT Roorkee: Dr. Basheer Ahmed
Special Silver Jubilee Awardees at AIMTDR 2012, Jadavpur University
Dr. D. R. Prasada Raju
Prof. S. R. Deb
Prof. H. S. Shan
Shri P. Mohanram
Prof. N. Ramaswamy
INVITED TALKS
Conference Center
Main Gate of IIT Guwahati
Invited Talk-1
Professor H. Hocheng
Department of Power Mechanical Engineering
National Tsing Hua University, No. 101, Sec.2, Kuang Fu Rd., 30013, Hsinchu
Taiwan, ROC
[email protected]
GREEN RECYCLING FOR SUSTAINABLE MANUFACTURING-A
MICROBIOLOGICAL APPROACH
Numerous industries discharge a variety of toxic heavy metals into the environment. These industrial
wastes are available for recovery and utilization of metals. The reuse of such materials not only conserves the
non-renewable resources but also solve the problem of environmental pollution. Conventional processes like
pyro and hydrometallurgical techniques are not economical and they themselves generate secondary pollution.
Therefore, there is a need to utilize more efficient technologies to recover heavy metals from secondary
sources. Biohydrometallurgy offers an attractive option, as it is safe, cost-effective and efficient. This process
can be carried out in close loop generating minimum effluents and thus is preferred as green technology.
Considering these benefits we used various microorganisms for recovery of metals from industrial wastes. A
two-step bioleaching process for recovery of metals has been developed. It was found that comparable
leaching efficiency achieved by simply providing culture supernatant. There is no need of microbial cells to be
present themselves for the bioleaching of metals. For an industrial application, the direct growth of organisms
in the presence of industrial waste is not advisable. Therefore, a two-step process separating microbial growth
from metal leaching process seems appropriate to increase leaching efficiency. We used culture supernatants of
Acidithiobacillus ferrooxidans (At. ferrooxidans), Acidithiobacillus thiooxidans (At. thiooxidans), and
Aspergillus niger (A. niger) for recovery of metals from button cell batteries, waste solders, thermal power
plant fly ash, and steel industry slag. A study was carried out for removal of silver from silver oxide zinc
button cell batteries. About 98% silver was dissolved in 1 h, at an initial pH of 2.5, 30 oC temperature, 150 rpm
shaking speed and by 50 ml At. ferrooxidans culture supernatant. A use of only culture supernatant for silver
extraction indicated that an indirect non-contact leaching was the predominant mechanism for metal
solubilization. Hence the role of At. ferrooxidans was most likely to regenerate Fe3+ as an oxidant. Another
study was carried out for bioleaching of metals from solders. Tin-copper (Sn-Cu), tin-copper-silver (Sn-CuAg), and tin-lead (Sn-Pb) solders were used in this study. Also efficiency of A. niger and At. ferrooxidans
culture supernatants was compared for metal removal from the solders. It was found that A. niger culture
supernatant removed metal faster than the culture supernatant of At. ferrooxidans. Also, the metal removal by
A. niger culture supernatant was faster for Sn-Cu-Ag solder as compared to other solder types. About 99%
metal dissolution was achieved in A. niger culture supernatant. An optimum solder weight for bioleaching was
found. For industrial solid waste materials coming from thermal power plant and steel industry, the
conventional bioleaching with ferric iron may not be feasible. In these industrial wastes the metals are present
mainly as oxides, carbonates and silicates rather than sulfides. For these wastes, it is easier to leach metals via
acids generated by microorganisms rather than conventional bioleaching with ferric iron. At. thiooxidans
culture supernatant was used for bioleaching of metals from Electric arc furnace (EAF) slag sample. Maximum
metal removal was found for magnesium. Repeated bioleaching cycles increased metal removal from 28 to
75%, from 14 to 60% and from 11 to 27%, for magnesium, zinc and copper respectively. In another study A.
niger culture supernatant was used for bioleaching of metals from thermal power plant fly ash. During
bioleaching process around 100% metal removal was achieved in 4 hours for all metals except chromium 93%,
nickel 83%, arsenic 78%, and lead 70%. The process parameters including temperature, shaking speed and
solid/liquid ratio were optimized for bioleaching process. During this study experiments were conducted to
evaluate effect of fly ash on growth of mung bean (Vigna radiata) before and after bioleaching process. The
results indicate that the toxicity of fly ash towards mung bean (Vigna radiata) was reduced due to bioleaching
process. The authors also established an enzymatic bio-Fenton process for removal of metals from printed
circuit board. Glucose oxidase enzyme was used for in situ production of hydrogen peroxide and thereby to
carry out bio-Fenton process for metal removal from printed circuit board.
Keywords: Industrial waste; Metal; Microorganisms; Bioleaching, Enzyme; At. Ferrooxidans, At. Thiooxidans,
A. niger.
Invited Talk-2
Dr. Sumitesh Das
Head, Global R&D, Tata Steel Limited
Jamshedpur, India
CREATIVITY IN MANUFACTURING: DRIVERS FOR 2030
It is often said that “Necessity is the mother of all invention”. The evolution of human civilisation is
closely linked with creativity in producing artefacts and tools that helped survival and growth. In the Stone
Age, the nomadic and “hunting for food’ lifestyle meant that arrow heads be carved out by rubbing stones. As
humans settled down and took up farming, agricultural tools were developed. Survival also brought with it
conquest of new lands and territories – discovery of metal being the transition point. Till the 18th century,
production volumes were limited and could be managed by local artisans.
Science followed art and the industrial revolution of the 19th century drove elements of mass
production. Customisation meant flexibility in lines, reduction in inventory levels forced the Just In Time
concept, Quality consciousness drove Six Sigma, the industrial mantra of “more for less” drove lean
manufacturing.
The IT revolution and cheap computing power enabled the quick deployment of concepts such as
Computer Aided Engineering, Design, Analysis and Planning. As the digital world improved the bandwidths,
concurrent engineering came into being.
Over the next two decades, consumption and utility of manufactured goods is expected to rise exponentially.
The demand is expected to come from the emerging middle classes, especially from regions with high
population of Asia and Africa. The emphasis will be on manufacturing without waste and being able to
customise and integrate features with local flavours.
Three corner stones of manufacturing may need a relook. These are – DATA, MEDIUM and
EQUIPMENT. The first cornerstone, DATA, is the simplest to understand and program. Numerical control
and feedback loops have increasingly delivered precision and repeatability. DATA will need to be transmitted
and re-configured to meet local demands. The second, MEDIUM, is the material that is being transformed. In
future, deformation and shearing modes of manufacturing may give way to additive mode of manufacture. We
can see the early buds of 3D printing and rapid prototyping challenging the high temperature and high pressure
forming processes. Our ability to fuse materials in innovative ways will determine how far these emerging
technologies will move into regular production of mass customisable goods.
The third cornerstone is the EQUIPMENT that transforms the MEDIUM into a useful product using
DATA. The EQUIPMENT of the future has to be locally fabricated, driven with less or renewable energy and
recycle the waste (or generate bio compatible waste).
The lecture shall address these three cornerstones, their present status and their future in manufacturing.
Invited Talk-3
Professor V. K. Jain
Mechanical Engineering Department
Indian Institute of Technology Kanpur
[email protected]
MANUFACTURING: VISION FOR FUTURE
This lecture with the issues related to futuristic manufacturing in general and Micromanufacturing in
particular. The lecture starts with the definition of ‘Micromanufacturing’ and ‘Micromachining’ and then a
general classification of Micromanufacturing processes is discussed. It deals with manufacturing sustainability
which has three dimensions: economic, social and environmental. It cautions about certain
Micromanufacturing processes which are highly energy inefficient which ultimately become non- friendly to
environment. The most efficient and environment friendly process being claimed is Layered Manufacturing /
e-Manufacturing.
The second part of the talk starts with the definition of “micromachining”, and then divides
micromachining processes in traditional micromachining processes and advanced micromachining processes.
It further divides advanced micromachining processes into mechanical micromachining, thermal
micromachining, electrochemical micromachining, chemical micromachining and biochemical
micromachining processes. After discussing the working principle of various select advanced micromachining
processes, it gives interesting specific applications of different types of micromachining processes, for
example, micro filters for textile and food industries, scribing EXCIMER LASER on human hair, micro-mixer,
etc.
The third part of the talk deals with 3-D printing / e-manufacturing /Layered Manufacturing. It
enumerates what is manufacturing without the use of tools, machine tools, employees, assembly lines etc. It is
named as manufacturing without factory. It gives an example of The Vienna University of Technology’s 3D–
printed race car, approximately 285 microns long. It was printed in four minutes and many more examples.
Further, it enumerates the challenges being faced by GE engineers in making parts by additive manufacturing
to reduce the weight of the aerospace engine. According to engineers with GE Aviation, the challenges of
additive metal manufacturing are serious as the promises this technology holds. How else can you make an
aero plane engine 1,000 pounds lighter?
The fourth part deals with the specific applications of micro-casting of wires, pillars etc. Micro formed
parts such as micro gears, micro springs, micro fasteners etc. are shown. Certain examples are included which
mention interesting specific applications in thermal and fluid sciences for more efficient heat transfer and
applications in heat pipes. Certain applications in the area of IC engines, specially fuel injector nozzles
requiring micro holes for uniform distribution of fuel in the cylinder. It also shows various kinds of micro
sensors used in automobiles. Micromanufacturing has very high potential of applications in medical sciences,
namely, dental surgery, micro gripper, hearing aids, etc.
The fifth and the last part of the talk deals with nano-finishing. It tells about the working principle of
magnetic as well as non-magnetic nano-finishing processes, namely, CMP, AFM, R-AFF, MRF, MAF,
MRAFF, R-MRAFF, etc. The most important aspects of these nano-finishing processes are their applications
in aerospace engineering, automobile engineering, defense, and biomedical engineering. It has been
demonstrated how these processes can be exploited for low cost, high finishing rate of human implants such as
knee joint, hip joint etc.
The talk ends with following remarks:
1. To cope up the race with the advanced countries, for that matter, any country has to spend
enough money on the innovative R & D activities.
2. No matter how much you spend on R & D, dedicated team of young, intelligent, honest,
hardworking and sincere researchers is needed in a country.
3. Micromanufacturing and additive manufacturing (green manufacturing) will have an important place in
the manufacturing industries.
Invited Talk-4
Larmorti Wright Khongwir
General Manager (Technical)
Indian Oil Corporation Limited, Bongaigaon Refinery
P.O Dhaligaon, Dist. Chirang, Assam, India
GREEN MANUFACTURING AND SUSTAINABILITY
Today, entire world is engrossed in the upheaval in which machine dominates our way of life. The
Industrial revolution has redefined manufacturing and operation process also has set competition as the way to
success so much to say that Industrialization has become the tool of advancement. It has delivered comfort but
with threat to sustainability. The revolution has ignored the cardinal philosophy to maintain natural balance
and universal harmony. Climate change being visible is confronting the vary menace and the prospect of
growth of developing countries is facing a dampening effect. Therefore, the need of the day is Green
manufacturing and Sustainability.
Green manufacturing is about implementing any kind of improvement / substitution in the
manufacturing process which leads to a reduction in energy consumption, resource consumption, waste and
water usage. It is a process that in every step, that the production of a product, component or part of a system
becomes more sustainable. Companies are inventing green technologies and practices to produce
environmental friendly products.
Sustainability is about balancing the nature of development in meeting the today’s needs and at the same time
ensuring availability of necessary resources for future generations to meet tomorrow’s needs. Sustainability
gives us the opportunity to reflect on things which might not have been considered in the past. Issues like the
cost of energy, the rapidly changing energy picture has been a huge eye-opener in which some years ago
people paid less attention to it; the cost of water and availability scenario, its treatment and the condition in
which it can be discharged are things which are now coming into the mainstream dialogue and emerging as
key parameters with which efficiency of processes can be judged. The increasing cost of energy and scarce
resources have forced people to understand and pay attention to optimally use the resources or energy.
Sustainability is a great driver for innovation. It all lies in idea generation, innovation and relentless
execution by the people for the success of any programme. There are efficiencies and inefficiencies in the
processes and operations, one need to enhance efficiencies and check others. Many companies are putting
efforts to reduce the cost of production, eliminate wastes, taking various steps for productivity improvement
aimed at profitability and maintain high quality of their products.
Industries form a backbone of an economy by providing various final and intermediate products for final
consumption. Energy is an indispensible ingredient for almost all industries. Many leading companies are
taking energy efficient initiatives in order to reduce its consumption and hence energy costs in these industries.
Although conventional fuels still dominate energy basket, there has been an increasing focus on renewable
sources over the past few years.
It is time to account resource sustainability and “embedded costs”. Of late, companies have come up
with various sustainable business plans. The first set of drivers that one notices includes competitiveness,
product awareness, reputation and solid business strategies because people and stakeholders tend to prefer
companies having corporate sustainable development framework.
These approaches are not only a reduction in adverse environmental impacts but also an enhancement
in the financial bottom-line of the firm due to efficient and cost-effective process. One can actually make good
arguments as to what the total benefits are: including cost benefits, business benefits while abiding regulatory
issues.
Contribution of Indianoil towards Green Manufacturing and Sustainability
Across the world, atmospheric air quality has been adversely impacted by emission from automobile
tailpipe exhaust, industrial smoke stacks, thermal power plants, construction dust including debris and the
other by-products of a crowded and modernized urban existence. Simultaneously the rising incidence of a
range of health effects has been recorded and there is compelling evidence of a causative link of the former to
the latter, some very direct, few others somewhat direct and some in an associated sense along with other
factors. Thus purifying of the air will be good for citizens’ well-being.
It is true that deterioration in ambient air quality is not the sole source of stress on the lives and health
of our citizens nor is vehicular tailpipe emissions the only source of air borne pollutants. Nevertheless,
IndianOil being a good and responsible corporate citizen has taken up this task in emission management as part
of its business strategy. Along with the agenda of making a positive impact in the society that it operates in,
Indian Oil Corporation also holds itself accountable to deliver consistently what it promises to its stakeholders.
It is committed towards the community to develop techno-economically viable and environmental friendly
products and also maintain the highest standards in respect of safety, environment protection and occupational
health at all production units and installations.
Over several years, IndianOil has been working extensively on various technology strategies /
approaches for emission management in its own Research and Development Centre and also with various
Technology suppliers in order to convert the raw materials into clean fuels and lubricants. Various state-of-theart technologies have been installed which are in operations in IndianOil’s refineries, producing
environmentally friendly green fuel products meeting the latest sustainable environmental specifications.
To be a Sustainable Organization, in all its business operations IndianOil believes in the 3 pillars of
sustainability viz.: People, Planet & Profit. Whereas 2 of these pillars, i.e. ‘Profit’ & ‘People’ are being taken
care of by various arms of the Corporation, the ‘Planet (Environment)’ issue is a key focus area for the
Renewable Energy and Sustainable Development (RE&SD) group.
The 3 key elements of ‘Planet’, which are the thrust areas of RE&SD group are - Environment, Water
& Waste. The key aim is to make IndianOil a Sustainable Organization and ingrain the objectives of ‘towards
neutrality’ in carbon, water & waste (CWW) in the Corporation’s processes and actions. The objectives
were further strengthened by IndianOil’s Sustainability Policy which is as given below.
“IndianOil shall continuously strive to be the leading energy provider of the country and in that pursuit
follow sustainable practices and technological processes that are safe, efficient and environmentally
benign to the society.”
In pursuit of this Policy, IndianOil is committed:
•
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The RE&SD group of IndianOil has taken up the task of completing carbon and water footprinting of
the entire organization during 2013-14. Simultaneously, there has been progressive involvement in taking up
initiatives to reduce the Corporation’s ecological footprint, wherein mapping of green house gas emissions,
water consumption and waste generation was done on the principle of “measure before we can manage” it
was decided to undertake “as is” basis.
In the field of energy conservation the corporation maintains continuous thrust on energy conservation
at all its refineries and units through extensive performance monitoring and by keeping abreast of the latest
technological developments and global best practices. At IndianOil to promote Clean Energy, the corporation
recognizes Renewable Energy (RE) as an important tool to tackle the growing energy requirements of the
nation and for minimizing the carbon footprint. The corporation is expanding its green energy portfolio. At
present, it has built up generation capacities in the Solar & Wind spaces and plans to scale these up and thereby
integrating the economic and environment spheres of its business.
Green Campus of Indian Institute of Technology Guwahati
Invited Talk-5
Professor Alok K. Verma
P.E., CmfgE
Ray Ferrari Professor and Chair
Engineering Technology Department
Old Dominion University
Norfolk, Virginia 23529
[email protected]
LEAN SIGMA - CONVERGENCE OF TWO POWERFUL MANAGEMENT
PHILOSOPHIES – LEAN AND SIX SIGMA
Lean Six Sigma is a continuous improvement methodology that combines two of the most powerful
improvement engines available to organizations today. Lean provides mechanisms for quickly and
dramatically slashing lead time and waste in both manufacturing and business processes (Bicheno, 2004;
Achanga, 2006). Six Sigma presents the tools and organizational guidelines that establish a foundation for
sustained, data-driven improvements in strategically important, customer critical targets (Hoerl et al., 2004;
Arnheiter and Mayleyeff, 2005). Today, Lean Six Sigma has grown beyond these problem-solving roots and
now encompasses high-level analytical tools and deployment guidelines that give companies the means to
establish and maintain strategy-to-execution links. Spector’s (2006) comments summarize the impact of these
two philosophies, “Lean and Six Sigma are two of the most effective business-improvement techniques
available today.”
Implementation of each of the above philosophies by themselves was not providing intended
improvements. Despite widespread success with Six Sigma, Jack Welch, then CEO of GE commented about
the drawback of Six Sigma approach in controlling variation in lead time (GE Annual Report, 1998). On the
other hand, implementation of Lean provided immense benefits in reducing lead time but could not control the
variation within processes.
The fusion of Lean and Six Sigma was needed since:
•
Lean could not reduce process variation and bring it under statistical control.
•
Six Sigma alone could not improve process speed and reduce lead time.
Over the last ten years, Lean Sigma has developed into a comprehensive methodology that provides a
structured way to transform organizations to build competitive advantage, customer satisfaction and
shareholder return, as well as to achieve high performance (George et al,.2004; Arnheiter and Mayeyeff, 2005;
Brett and Queen, 2005).
The presentation will highlight the two philosophies and how they have evolved into a single comprehensive
solution for organizational productivity in today’s global economy.
Bibliography
Achanga, P. (2006), “Critical success factors for lean implementation within SMEs”, Journal of
Manufacturing Technology Management, Vol. 17 No. 4, pp. 460-71.
Arnheiter, E. and Maleyeff, J. (2005), “The integration of lean and six sigma”, The TQM Magazine, Vol.
17 No. 1, pp. 5-18.
Bicheno, J. (2004), “The New Lean Toolbox towards Fast and Flexible Flow”, PICSIE Books,
Buckingham.
Brett, C. and Queen, P. (2005), “Streamlining enterprise records management with lean six sigma”,
Information Management Journal, Vol. 39 No. 6, pp. 58-62.
George, M., Rowlands, D. and Kastle, B. (2004), “What is Six Sigma?”, McGraw-Hill, New York, NY.
Goodman, J. and Theuerkauf, J. (2005), “What’s wrong with six sigma?”, Quality Progress, Vol. 38 NO.
1, pp. 37-42.
Hoerl, R., Snee, R., Czarniak, S. and Parr, W. (2004), “The future of six sigma”, ASQ Six Sigma Forum
Magazine, Vol. 3 No. 4, pp. 38-43.
Liker, J. (1998), Becoming Lean, Productivity Press.
Naslund, D. (2008), "Lean, six sigma and lean sigma: fads or real process improvement methods?",
Business Process Management Journal, Vol. 14 No. 3, pp. 269 – 287.
Schonberger, R. (1986), World Class Manufacturing: The Next Decade, Free Press.
Feld, W. (2001), Lean manufacturing, tools, techniques, and how to use them, St. Lucie Press.
Spector, R. (2006), “How constraints management enhances lean and six sigma”, Supply Chain
Management Review, Vol. 10 No. 1, pp. 42-7.
Womack, J. and Jones, D. (1991), The Machine That Changed the World, Harper Perennial, New York.
Womack, J. and Jones, D. (1994), “ From lean production to the lean enterprise”, Harvard Business
Review, Vol. 72 No. 2, pp 93-103.
Womack, J. (1996), Lean Thinking, Simon & Schuster.
Invited Talk-6
Professor Kornel Ehmann
Northwestern University
Evanston, IL 60208
[email protected]
MICRO-TEXTURED ENGINEERED SURFACES
It is an undisputable fact that surface texture has a profound influence on the functional behavior and
responses of all engineering systems and products. Typical high-impact examples include: biomedical
applications (e.g., resistance to bio-film formation), energy production (e.g., algae-philic/phobic properties,
reflectivity of solar-cells), mechanical systems (e.g., friction reduction in machinery), etc. Yet, the current
scientific basis and technologies are limited in their ability to engineer and physically impart precisely
controlled surface textures that result in a specific engineering performance. In this presentation some of the
key R&D issues, with particular emphasis on the salient features of micro/meso-scale manufacturing process
developments that are needed for the realization of surfaces in terms of both topographical and physical
properties to meet precisely prescribed functional characteristics, will be given. Specifically, capabilities that
currently do not exist are be targeted. These are characterized by the following attributes: large surface areas,
high density surface features, “hard materials” (metals, ceramics, composites, etc.), and mass-production
rates/efficiencies that result in low cost.
Micro-texturing Processes and Examples
In the presentation examples of three classes of newly-developed micro-texturing processes at
Northwestern are introduced, i.e.: micro-cutting, -forming/rolling and -laser processing.
Micro-cutting. A vibration-assisted machining method is developed to generate different microstructures on cylindrical surfaces. The proposed elliptical vibration texturing process, utilizes
vibrations/modulations of the cutting depth at ultrasonic frequencies for the fast generation and control of
micro-features ranging from micro-dimples to micro-channels. The configuration and dimensions of these
micro-structures play a crucial role in the surface’s functional properties. The principle and an example of a
micro-textured cylindrical surface are shown in Fig. 1.
Fig. 1. Elliptical vibration texturing principle and example in turning
Micro-forming. Among the existing surface texturing methods micro-forming and, in particular, microrolling holds the greatest promise for high- rate texture production. To meet the growing demands for the
generation of desired textures on hard sheets such as stainless steel and titanium warm/hot forming can be used
to ease texture formation. In order to elevate the workpiece’s temperature for warm/hot micro-rolling, electric
current was introduced into the rolling process to carry out electrically-assisted micro-rolling. When an electric
current passes through an electrical conductive material, the ensuing Joule heating effect leads to rapid heating
that results in the reduction of the material’s flow stress that, in turn, eases texture formation. Figure 2 gives a
schematic representation of the micro-rolling machine and an example.
Fig. 2. Micro-rolling machine and example
Micro-laser-processing. Laser Induced Plasma Micro-Machining (LIPMM), a recently pioneered
process, has demonstrated promising micro-machining capabilities such as multi-material capability, higher
aspect ratio micro-structures, less heat-affected distortion and higher material removal rates as compared to
conventional pulsed laser micro-machining. Two modifications of the LIPMM process are introduced for
plasma manipulation that are aimed at the control of the geometry of the machined features and for increasing
texturing efficiency. One method utilizes strong magnetic fields while the other optical means to shape the
plasma. The principle of LIPMM, rooted in plasma generation in a dielectric just above the workpiece surface
that leads to material removal, and examples of machined features by the two methods is given in Fig. 3.
Fig. 3. Laser-induced plasma micromachining (LIPMM) with optical and magnetic field plasma manipulation
Numerous application examples of micro-textured surfaces will also be presented.
Invited Talk-7
Professor Kamlakar P. Rajurkar
Industrial and Management Systems Engineering
Mechanical & Materials Engineering
University of Nebraska Lincoln
Lincoln, Nebraska, USA
NATURE–INSPIRED FUNCTIONAL SURFACES AND THEIR APPLICATIONS
1
K. P. Rajurkar1 and A. P. Malshe2
University of Nebraska-Lincoln, USA
2
University of Arkansas, USA
Nature has been developing many almost –perfect materials, processes and systems at nanoscale to
macro scale and even at extremely very large scale during the millions of year’s evolution. Biological species
have been battling and surviving extreme environmental conditions since the beginning of life on earth. The
continuous evolution is an ongoing process. In particular, biological surfaces, which are the active interfaces
between subjects and the environment, are being evolved to a higher state of intelligent functionality. These
surfaces have become efficient by using available materials and unique physical and chemical strategies.
Physical strategies such as texturing and structure, and chemical strategies such as sensing and actuation are
two important examples. These strategies enable functional surfaces to deliver extraordinary adhesion,
hydrophobicity, multispectral response, energy scavenging, thermal regulation, anti-biofouling, and other
advanced functions. Manufacturing industries can learn and apply such biological surface strategies in order to
generate clever surface architectures and implement those architectures to impart advanced functionalities into
manufactured products.
This keynote paper presents a state-of-the-art review of such inspiring biological surfaces and their
non-biological product analogs, where manufacturing science and engineering have adopted such advanced
functional surface architectures. In particular, the paper addresses the importance and need for generating
natural surfaces including examples of adhesion, super-hydrophobicity, optical engineering, optical tuning,
anti-biofouling, hard and tough surfaces, energy scavenging, and external stimuli sensing. An integrated
approach using physical, chemical, and functional attributes for architecture design which includes texturing,
chemistry, multiple scale shapes, and complimentary subsurface is also discussed.
The importance of a better understanding of Nature’s advanced functionalities for generating products
for social needs and related manufacturing science, engineering and sustainable consumption is discussed.
Specifically, generation of adhesive surfaces, super hydro-phobic surfaces, cutting tool surfaces, optical
surfaces, and actuating and sensing surfaces will be described.
Although not directly related, this paper will also cover few aspects of bio-manufacturing. The paper
will address core themes of bio-manufacturing including bio-specific design constraints, bio-mechatronics,
bio-fabrication, and bio-design and assembly. It will also highlight the state-of-the-art research, challenges,
future potential and opportunities and applications.
Invited Talk-8
Professor N. K. Mehta
Emeritus Fellow
Department of Mechanical & Industrial Engineering
Indian Institute of Technology Roorkee
SUSTAINABLE MANUFACTURING
.Sustainable manufacturing is manufacturing that consumes minimum energy and resources and causes
minimum damage to environment. In respect of discrete manufacturing this translates to minimizing the
amount of machining to obtain a component of the desired accuracy and surface quality. In traditional discrete
manufacturing, components are made from blanks from which the extra material is removed by machining and
is a form of waste unless properly recycled. This is known as subtractive machining. A recent alternative to
subtractive machining is additive manufacturing in which a component is directly built layer-by-thin layer so
the there is no blank and no wastage.
SUSTAINABILITY ISSUES IN SUBSTRACTIVE MANUFACTURING:
Making blanks as close as possible to the finished component holds the key to sustainability in
subtractive manufacturing as regards consumption of work material. Large machining allowance not only
involves waste of material in the form of chip, but also enhanced machining and chip handling costs .Blanks
for machined components are obtained in two ways:
1.
Blanks that are cut to size from standard rolled products such as billets, plates, sheets, bars etc and
special rolled sections such as I, channel, angle etc.
2.
Blanks that are obtained individually by casting or forming (forging, extrusion etc).
Blanks from standard/special rolled sections
The classical method of production of standard and special rolled products involved production of
ingots and their primary rolling into slabs, blooms and billets. Additionally, secondary rolling was required to
produce plates and large diameter pipes from slabs, structural shapes, strips and tin plates from blooms and
bars of various sections and wires from billets. The most revolutionary step towards sustainability of blank
production was the invention of continuous casting, also called strand casting which eliminates the need for
blooming and slabbing mills, drastically reduces the production time, increases the yield to 96-99%, provides
energy saving of 25-50%, eliminates the metal loss of 15-20% due to cutting of the ingot head and gives
product of better and consistent quality. Continuous casting was introduced in India in early 1970’s, but now
provides around 80% of all rolled sections produced in the country.
Ongoing research and the recent developments in continuous casting are electromagnetic stirring of
liquid steel in the mold that transforms the structure from columnar to equiaxed and then to globular. Heat
transfer studies in tundish and ladle, use of different flow modifiers for inclusion removal in ladle and tundish
and studies on mold shape (taper, curve), mold flux and mold lubrication combined with the improvements in
design features of tundish has helped to increase the average casting speed from 2m/min to 4m/min.
Integration of continuous casting with secondary rolling in a single continuous flow provides energy saving
and higher productivity by eliminating reheating. Development of liquid core reduction technology and
improvements in nozzle and mold design and secondary cooling system allows the solid billet with liquid core
to be subjected to on line rolling in near net shape casting units, known as casters. Evolution of the layout of
continuous casting machines from vertical to bow to vertical bending type combines the high efficiency of
inclusion and bubble removal of the vertical machine with the high productivity of the bow machine. However,
now horizontal continuous casters are being used for billets and blooms. This layout reduces plant vertical
height to 1/3-1/2 of the vertical design, requires no spray cooling because ferrostatic pressure is low and it does
not require strand bending and unbending.
Individual cast blanks: Net and near net casting processes
The traditional method of making blanks in a foundry is by sand casting. These casting have large
tolerances due to factors such as draft allowance, rapping allowance, shrinking allowance etc. which
necessitates substantial amount of subsequent machining. However there are several special casting methods
that are accurate enough to minimize and even eliminate the need of further machining. The economic
feasibility of these special casting methods is related to the production volumes, size of the casting and
material of the casting among other factors, therefore, their ability to produce precision blanks must be
weighed against the enhanced cost in each individual case.
Some of the well known methods that have found application in industry are shell mould casting,
evaporative pattern casting, centrifugal casting, die casting, shell lined die casting and investment casting. A
hybrid of gravity die casting and closed die forging known as squeeze casting produces near net shape
components in metal alloys and composites. Rheocasting and thixocasting are two methods of making
precision castings with the help of semi-solid slurry. Vacuum moulding (V-process) is a variation of the sand
casting process for most ferrous and non-ferrous metals, in which unbounded sand is held in the flask with
vacuum.. Gel casting is a new ceramic forming technique getting worldwide attention. The process is based on
the casting of slurry, containing powder, water and water-soluble organic monomers.
Individual forged blanks: Net and near net forming processes
Among the forging methods, close die and flashless impression die forging are precision forging
processes capable of giving near net and net shape blanks. Other near net shape forming methods are cold
forging or cold extrusion for forming of bulk material at room temperature generally of axi symmetric shapes,
hot extrusion, upsetting, coining, ironing and swaging. Warm forging which is forging at 700-8000C i.e below
the recrystallization temperature is employed to reduce the flow stress. Isothermal forging and hot die forging
are finding application in closed die forging with and without flash of titanium alloys, aluminum alloys and
nickel base super alloys for aircraft and space industries. Enclosed or trapped die forging using multiple action
tooling as punches is finding application in flashless forging of net shapes at low forming loads. Laser forming
has become a viable process for the shaping of thin metallic components. Spray forming, also known as spray
casting, spray deposition and in-situ compaction, is a method of casting near net shape metal components with
homogeneous microstructures via the deposition of semi-solid sprayed droplets onto a shaped substrate.
The current achievable tolerance in machining is ± 1micron, whereas in cold forging it is ±20-50 microns. For
cold forging techniques to compete with machining their accuracy would have to be increased to ±10 micron
or better. The issues that need to be addressed to meet this target are as follows: Die manufacturing – cemented
carbide dies are required instead of HSS dies, because of their high stiffness, low thermal effect and high wear
resistance. Also TiC, TiN and TiCN coatings are applied on the die surface to reduce wear. Use of EDM has
considerately improved the accuracy of forging dies; Die deflection- can be minimized by taking care of the
thermal expansion, creep and lowering of modulus of elasticity at high temperature; Press deflection- this can
be minimized by considering the following factors: clearances in the guiding system, horizontal offset & tilting
during multi stage forging or forging of complex parts, deflection of press frame & cross head. Both die and
press should be subjected to rigorous FEA and simulation and the results incorporated in their design.
Sustainable machining
When the blanks are net shape, there is no need of any further machining. When the blank is near net
shape, a small allowance has to be removed by machining in one or more finishing cuts. If the work piece is in
heat treated state then finishing is done by grinding operation. Non heat treated work pieces are finish
machined by conventional machining operations. Grinding is an abrasive process that is carried out at high
cutting speed of 30-50 m/sec under flood cooling. The grinding swarf is difficult to collect and the abrasive
dust and cutting fluid pose ecological problems. Machining with CBN tools is emerging as a sustainable
alternative to grinding. CBN tools are increasingly being used on lathes (hard turning) and milling machines
(guide way machining). The MRR in hard turning is 4-6 times of the equivalent grinding operations. Being non
dry and non abrasive, hard turning is more environment- friendly. The hard turned chips are easier to collect
and less costly to dispose off than the grinding swarf. The main challenge lies in the designing precision high
speed machine tools of high static stiffness and dynamic stability.
Finish machining of non heat treatable work pieces by conventional operations such as turning, milling,
drilling etc is carried out at high cutting speed under flood cooling. The mineral oils used in cooling are
hazardous to operator, causing respiratory disorders and skin diseases. Coolant cost may be up to 30% of the
manufacturing cost. Near dry machining is emerging as sustainable alternative to wet machining. Coolant
consumption in MQL and MQC is 10-100ml/hr used as 5-10% emulsion at 4-6.5 bar pressure. Vegetable oils
used in MQL are bio degradable and non toxic. They have low volatility and higher flash point that reduces
smoke formation and fire hazard. The coolant is supplied as a mixture of emulsion and air in the form of
aerosol, therefore it has better penetration in to the cutting zone and provides more efficient cooling. Fluid
supplied to the cutting zone is consumed at once, so there is no need of fluid monitoring, collection and
disposal. There is reduction in solid waste by 60% and water use by 90%. Better visibility of operation
improves safety and there is significant cost saving.
Efficient chip breaking by proper selection of machining parameters and incorporation of chip breakers
in cutting tool design can have enormous impact on chip collection and disposal. For effectively broken chip,
the handling cost may be a fraction of that for long spiral chips.
Tool waste is significantly less than work
material waste. The interesting aspect is that the important component of the tool waste is not the portion that
is worn during the cutting process, but the remaining portion of the tool which is disposed of after its useful
life. The expended tool can be of HSS, carbide or ceramic metal composites. The presence of elements such as
Ni and Co in cemented carbide tools and various types of abrasives in ceramic tools makes its essential that
abundant caution be exercised in their collection, storage and disposal.
ADDITIVE MANUFACTURING
Additive manufacturing is a term which embraces a range of technologies for producing accurate parts
directly from CAD models. The 3-D model of an object is sectioned into an integrated series of 2-D slices.
Each 2-D slice is built by a process of material accretion and thus the full object is built layer-by-layer stacked
on each other. By convention the object is sliced in the X-Y plane and built in the Z direction. The sliced layers
are very exact in the X-Y plane, but have stair-stepping effect in the Z-direction. If the slicing is done in very
fine layers then accurate products can be made, though the time of building the object increases with the
reduction of step size. The principal application of additive manufacturing approach has been in rapid
prototyping as it can cut new product costs by upto 70% and the time to market by upto 90%. With these
features, it is possible to go through multiple design interactions within a short time and substantially reduce
the product development time. However, with advances in the technology, it is now developing as a serious
competitor to conventional subtractive manufacturing for regular production of a range of parts, because it
does not involve any substantial tooling or special fixturing and is zero-waste by its very nature.
Several technologies of additive manufacturing have been developed. The main differences among these
technologies are in two aspects: 1) material used and 2) part building technology. Some of the important
technologies are: Stereo lithography (SL) in which the material used is liquid photo curable resin acrylate and
curing of the photopolymer pool is carried out by a laser which is controlled to trace the 2-D section on the
liquid surface and produce the particular layer; Liquid thermal polymerization (LTP) is similar to SL except
that the resin is thermosetting and an infrared laser is used for curing; Solid ground curing (SGC) also known
as photo masking utilizes photo polymerising resins and light as the curing source; Fused deposition modeling
(FDM) uses molten material, usually a thermoplastic which is deposited through a nozzle whose movement is
controlled to trace the 2-D section, Selective laser sintering (SLS) uses material in the form of powder which is
heated with CO2 laser of 25-50 W range to sinter the material that falls in the path traced by the laser.
Basically, all materials that can be pulverized may be used in this process. At present it has been tried on nylon
composites, sand, metals and polycarbonates; Three-dimensional printing (3-D Printing) also uses a powder
material. Layers of powder are applied to a substrate and the portion corresponding to the 2-D section is cured
using a binder sprayed through a nozzle. The part is sintered at 9000C for 2 hrs. The green part may be pressed
isostatically before the final sintering to increase its density. The materials used in this process are metals or
ceramic powders and metal-ceramic composites.
The biggest challenge in additive manufacturing is to produce industrial metal structures, especially
from expensive materials. For example, in aircraft manufacturing the standard procedure is to machine the
metal structure from a solid billet. The buy to fly ratio of these structures is on an average 5 to 6, which means
that for every kg of material on the aircraft about 5-6 kg is initially required. For expensive composites or
titanium such wastage becomes untenable. But, although selective laser sintering (SLS) is a good prospective
technology, it suffers from productivity constraints. For instance, in the powder bed variant of SLS, the
productivity is merely a few tens of grams an hour. Research carried out at IIT Bombay has displayed
significant improvement in productivity. With wire as feed stock not only is the material cost several times less
but the productivity is also higher. In the wire + arc AM (WAAM) method using MIG as the heat source, the
productivity has been reported as 2-4 kg/hr with a fly ratio of 1.2. The current research is focusing on strip as
the feed stock with MIG as well as laser heat sources. For complex structures, hybrid AM + machining is an
approach that is being researched where the layer height build errors are corrected by machining after one or
more layers. This can compensate for the coarseness of deposits that restricts the level of complexity of the
structures. The multi axis part manipulation is done using 5-axis machining center combined with wire + laser
AM (WLAM).
Additive manufacturing has an advantage only for such parts that are impossible to make by
conventional methods or are cost prohibitive because of large wastage of expensive material. AM parts still do
not match the surface quality of CNC machined parts. Therefore, if a part can be produced at reasonable cost
and the volume is relatively high, the conventional route may still be the better one. In the past AM was used
mainly for RP purposes. Now many organizations such as Boeing, GE aviation are focusing their energy on
qualifying AM processes and materials to make parts that go into final products. As organizations qualify and
certify more materials and processes, the AM industry is poised to become the most strategic and the most
used manufacturing technology.
HOLISTIC VIEW OF SUSTAINABILITY IN MANUFACTURING:
The individual manufactured components form part of a sub assembly or assembly and ultimately the
final product. Therefore the product life cycle assessment (PLCA) approach only can give true idea of overall
sustainability. Seen in this broader context, it is essential to consider not only the physical waste streams of
work material, tool material and cutting fluid, but also the end of life issues of product, namely disassembly,
reuse, remanufacturing and recycling.
In order to make sustainability a central issue in manufacturing, it is necessary to develop integrated
process models in which the traditional parameters such as production rate, quality and energy are expanded to
include the penalty cost of the health hazard from all the waste streams - work material, tool and cutting fluid.
For this, research on scoring scheme for various health hazards - toxicological, carcinogenic, chemical
reactions, flammability etc and multi objective optimization models needs to be encouraged and strengthened.
Equally important is the impact of product design on the sustainability during manufacturing and the
various end of life aspects. Advances in CAE, CAD, FEM and related areas have made it possible to enhance
the reliability of design calculations, thereby limiting overdesign to minimum. Application of quality function
deployment (QFD) at the initial stage of the formulation of design specifications is making the design
procedure increasingly holistic whereby the issues of manufacturability (DFM), assembly (DFA) and the end
of life issues are all given due weightage in the product design.
Invited Talk-9
Professor V. Radhakrishnan
Formerly with IIT Madras and IIST, Trivandrum
Email: [email protected]
APPLICATION OF ELASTIC ABRASIVES FOR FINE FINISHING
Introduction
Surface finish of manufactured parts played a critical role in their functional applications. Often an
optimal finish is needed for any specific functional needs. Advances in microelectronics and related fields
brought into focus the need to achieve ultra fine finish on parts and components for their functional
performance and reliability. This led to the development of a number of new approaches for fine finishing of
surfaces without altering their form. Fine finishing needs uniform material removal in very small quantities
leading to long processing time. Hence the complexity and cost of finishing operations shoot-up when the
finish needed is in the range of 50nm Ra or lower.
Currently there are many competing processes that have demonstrated their ability to achieve such
order of surface finish. These include Abrasive Flow Finishing, Magnetic abrasive finishing, Magneto
rheological finishing, Magneto rheological jet finishing and Ice bonded abrasive polishing. Fine abrasive
grains under controlled finishing pressure removes the material at the nano scale leading to ultra high finish on
the part. Micron and sub micron abrasives are ideal for these operations because of low finishing force, fine
cutting edges, reduced depth of penetration and more number of active grains per contact area, leading to nanoscale material removal and ultra fine surface finish. This calls for controlling the depth of penetration of the
abrasives in all such processes. Different approaches could be thought of to achieve this and one is by selecting
the right bond to hold these abrasive particles. This could be a semi-viscous or magnetic media for holding the
abrasives that is flexible to accommodate the form variations.
Elastic Abrasives
The term elastic abrasive refers to abrasive particle bonded in an elastic media. These may be made in
the form of small spheres of different diameters made of abrasives and elastic bonding material. Such elastic
abrasives are easy to make, handle, apply and clean. Further their stiffness can be changed by changing the
proportion of the elastic bond and the abrasives embedded on them. These elastic abrasive spheres of 3 to 8
mm diameter can be made in good quantities using the right elastic media and micron or submicron abrasive
grains of different types. They can be used either in dry condition or with a cooing medium like water. High
resilient elastomeric polymer beads having good mechanical, thermal and chemical stability are used for the
preparation of elastic abrasives. A direct chemical approach is followed to develop the elastic abrasives, in
which fine grits of abrasives were embedded on the polymer beads together with some additives.
Fig.1 Elastic abrasives and the finishing set-up for internal bores
Elastic Abrasive Finishing
Any process to be of advantage should be simple and versatile as far as possible. Elastic abrasive
finishing meets these demands in an excellent fashion. The hardware requirements for their application are
relatively simple, less energy consuming, environment friendly and amenable to recycling. They can be
applied in different ways allowing their applications in different contexts. These include squeezing of these
balls on to the surface to be finished and allowing relative motion between them, leading to micro cutting
action. They can also be made magnetic by embedding magnetic particles in addition to the abrasive particles.
These magnetic elastic abrasives can be conveniently used in the presence of a magnetic field, like magnetic
abrasive finishing. Another application of this abrasive spheres is in fluidized abrasive finishing. As against
fine and sub micron abrasive particles that are not amenable to fluidization, the macro sized elastic abrasive
spheres can be easily fluidized allowing to achieve nano scale finish on any surface including free form
surfaces.
Application Examples
Application of elastic abrasives in different modes for fine finishing allows this approach to a versatile.
It can be used conveniently for finishing internal bore surface as well as for oval or other cross section bores.
Likewise it can be used for external cylindrical surface with convenience. An interesting application is in the
finishing of internal circumferential grooves which is not easy by other means. Using fluidization, these
abrasives can be impacted on flat or free form surface and excellent finish could be achieved by fine erosion of
the surface. It is easy to make these elastic abrasives balls magnetic by embedding suitable magnetic material
in the elastic media. Such elasto magnetic abrasives could be held together by magnets and moved over the
surface for fine finishing.
Results of elastic abrasive finishing
The following table gives in brief the improvement in surface finish on different parts using these abrasives:
Workpiece
Cylindrical bore
Oval bore
Internal groove
[circumferential]
Flat Disc
Flat Disc
Material
Hardened Steel
Hardened Steel
Stainless Steel
Hardened Steel
Steel
Initial Ra ( m)
0.158
0.2
0.5
0.18
0.18
Final Ra ( m) Action
0.018
Abrasive
0.02
Abrasive
0.013
Abrasive
0.027
0.04
Erosion
Abrasive
Time
40 m
40 m
50 m
40 m
60 m
Conclusions
Nano scale finish is easily achievable through the application of elastic abrasives, in different modes to suit the
part geometry. The procedures are simple, cost effective and to a great extent environment friendly. Added to
this, the cleaning of the part after finishing is easy and the elastic abrasives can be reused. This has opened out
various possibilities for fine finishing in manufacturing.
References:
1.
Sooraj, V.S., Radhakrishnan, V. (2014), A study on fine finishing of hard workpiece surfaces using
fluidized elastic abrasives, International Journal of Advanced Manufacturing Technology, DOI
10.1007/s00170-014-5889-1.
2.
3.
4.
5.
6.
Sooraj, V.S., Radhakrishnan, V. (2013), Feasibility study on fine finishing of internal grooves using
elastic abrasives, Materials and Manufacturing Processes, Vol. 28, pp. 1110–1116.
Sooraj, V.S., Radhakrishnan, V. (2013), Elastic impact of abrasives for controlled erosion in fine
finishing of surfaces, Manufacturing Science and Engineering (ASME), 135(5), 051019(2013)-DOI
:10.1115/1.4025338.
Sooraj, V.S., Radhakrishnan, V. (2014), Fine finishing of internal surfaces using elastic abrasives,
International Journal of Machine Tools and Manufacture, Vol. 78, pp. 30-40.
Jaganathan, R., and Radhakrishnan, V. (1997), A preliminary study on fluidized bed abrasive polishing.
Transactions of NAMRI/SME, Vol. 25,189-194
Sooraj, V.S., Radhakrishnan, V. (2012), Impact wear as a surface finishing technique: approaches and
assessments, Proceedings of 4th International and 25th All India Manufacturing Technology Design and
Research (AIMTDR) Conference, December 14-16, 2012, Kolkata.
Invited Talk-10
Professor Sanjay Kumar
Professor, Operations Management,
Management Development Institute, Gurgaon India
EXPLORING THE INTERACTION OF PEOPLE, SYSTEMS AND TECHNOLOGY IN
COMPLEX PROCESS MANAGEMENT CONTEXTS
Work in large organizations is often executed through complex processes, the management of which
may involve thousands of people, and a proportionately large assets base. These processes are sequences of
activities, which when executed result in products and services to meet the needs of the customer. Since the
output of these organizations depends on the repeated execution of these complex processes, their design and
working is of critical interest to the organization.
In such complex process management contexts, there is an interaction of systems (as in organizations
and systems), technology and people interact. Systems include the organizational structure, management
systems and processes, through which organizational work is executed. Technology includes Information
Technology (IT) and the product and manufacturing process technology of the organization. In people
generally the managers of the organization and the workers are included. Each ‘manager’ or engineer comes
with his own set of personal goals and acquires some organizational goals. Congruence between these personal
and organizational goals is required.
The interaction of systems, technology and people happens in many ways and research has shown that
technology and technological systems are seldom used as designed. People use technology and systems to
solve problems and to manage these complex processes efficiently. People use technology and systems in
various innovative ways. Group working and organizational processes further constrain and modify the useage
of systems.
Research has been conducted into this interaction of people, technology and process (or systems) and has
improved the design of the technological systems, with regard to usefulness, ease of use, and robustness of the
solutions. The organizational and process context is captured by the individuals in their behavior, while
working as individuals and in groups . Thus group behavior norms modify the “ framing” of the problems in the
organizations. This leads to a change in the problem formulation, and hence the solution has to be different.
Thus often ‘technological systems’ are caught short in terms of not being to handle the “ new” problem as
“ framed” by the organization.
The speaker uses the example of a recent large study into the ‘non-compliance’ of managers with the
output schedules of ‘advanced planning systems’ , to discuss the importance of studying the interaction
between people, technology and process.
Here “ non-compliance” is taken as a ‘deviant behavior’ on part of the managers, the cause for which has to be
investigated. The most general cause for ‘deviant behavior’ is a mis-match between the design and working of
systems, technology and people. When ‘managers’ find that the solutions suggested by the IT systems do not
improve their results in their area of responsibility, they try different solutions which may be at variance to the
designed system. However if it improves their performance on the job in terms of their ‘key responsibilities’ ,
then these ‘innovative solutions’ are adopted.
‘Advanced Planning Systems (APS) are multi- million dollar large software systems, which use
complex algorithms to optimize the usage of resources in an organization’ s supply chain. The implementation
involves teams of about 30-40 managers who work for about 6- 10 months to implement the systems.
Complex organizational processes embedded into these Advanced Planning Systems (APS) must be
designed so as to deliver the products and services to the customer, with minimum resources and in time. The
‘process design’ has to be such that the organizational goals and the ‘manager’ s goals’ should be aligned in the
same direction.
The study focuses on the decisions taken by the managers with assistance of the APS. Then three contrasting
perspectives - the ‘process perspective’ , the ‘people perspective’ and the ‘Optimization system’ perspective are
used to show how the “ design of the critical decisions” is structured in the IT system. Then the process and
people context (including group working) is used to show how the decision is “ re-framed” . Thus the problem
which the IT systems is designed to solve is no longer the problem to be solved. Thus the system is inadequate
and is not able to solve the “ re- framed” problem.
This research suggests a wholistic re-design of the IT systems so as to incorporate fuzzy formulation s,
multi-criteria formulation, and group decision with negotiated decisions.
Invited Talk-11
Professor M.S. Shunmugam
Professor, Manufacturing Engineering
Indian Institute of Technology Madras, Chennai-600036
MACHINING RESEARCH: SNORKELING OR SCUBA DIVING?
Machining is an important operation in the manufacture of almost all engineering components. A wide
range of sectors such as energy, automotive and space use machining extensively in the manufacture of various
components, apart from consumer product sector. Even though attempts are made to manufacture near-netshape parts, they also require machining of functionally important surfaces to some extent. The scope of this
presentation will be limited to metal cutting in which material is removal by shearing action of a harder tool.
The tool must be able to retain the cutting ability even at higher temperatures as encountered in the metal
cutting. The cutting elements are arranged on the cutter body according to the type of operation, namely
turning, drilling, shaping, broaching, milling, etc. In case of grinding operation, abrasive grains bonded in a
suitable matrix act as cutting elements. Metal cutting technology has undergone several changes in terms of
development of machine tools and cutting tools to meet challenges posed by newer materials, complex shapes,
product miniaturization and competitive environments.
There are two distinct approaches to carryout machining research: one at surface level and the other
one to go in-depth to understand the phenomenon. Taking turning of steel workpiece as an example,
experiments can be carried out with different combinations of independent variables, namely work-material
(soft/hardened, cryo/hot condition), cutting tool (geometry, material, coating), cutting fluid (dry, flood, mist,
MQL) and cutting parameters speed, feed, depth of cut). The final objective is to obtain quality products
(dimension & form accuracy, surface finish, residual stresses) at a desired productivity level (metal removal
rate, MRR). Machining economics also plays an important role in a competitive environment. On-line
assessment of product characteristics always poses certain practical difficulties. Hence process responses are
investigated in terms of cutting forces (tangential, feed, radial), cutting temperature, vibration, acoustic
emission, tool wear and chip morphology; the last two responses namely tool wear and chip morphology are
often studied off-line. Several experimental plans are available through design of experiment approach,
covering full factorial, fractional factorial, rotatable composite designs and orthogonal arrays such as those
proposed by Taguchi. Once an experimental plan is finalized, the process is thereafter conveniently treated
like a black box. Even a basic fact that turning operation is a displacement-controlled process and MRR can be
directly determined from the cutting parameters like speed, feed and depth of cut is often ignored.
Experiments are conducted according to the chosen experimental plan and with a view to study the
effect of a set of dependent variables with a set of selected independent variables. No doubt, large amount of
data is generated and the same can be represented in different ways, tables, plots, bar-charts, etc. Explanations
are offered using the basic facts and well known process mechanics. The most disheartening trend is to
explain the process behavior without knowing the principles and capabilities of the measuring instruments.
Orthogonal arrays proposed by Taguchi simplify the analysis of effects of controllable variables on response
variable. With a number of statistical packages being available, statistical tools like regression, ANOVA, etc.
are used to bring out the significance of controllable variables and their interaction on the response variables.
Unfortunately this approach does not bring out the process mechanics. These are good for understanding the
process in its surface level.
It is generally felt that the appropriate models will lead to more generalization and better understanding
of the process. Hence, attempts are made to develop empirical models based on statistical and AI techniques.
Regression and ANN models are some typical examples. These models predict the response variables within
the region of experimentation with certain accuracy, but fail miserably outside the region. Several
optimization methods such as statistical and meta-heuristic techniques (genetic algorithm, particle swarm
optimization, ant colony algorithms etc.) are used to obtain optimal parameters using the models developed.
There are instances wherein the empirical models are used without examining the nature of the so-called
objective function and the optimal parameters are at the extreme boundaries of the chosen region. One has to
remember that optimization is only a compromise between conflicting requirements. None would like to
continuously improve surface finish, sacrificing the productivity. It must also be remembered that a single
operating point cannot be sustained in practice, in view of the variability associated with the process itself and
some of assignable causes like tool wear, material anisotropy, etc. The practical strategy must be to run the
process with a satisfactory performance over a given period of time.
The mechanistic models are based on phenomenological reasoning that is able to bring out the process
behavior, but certain constants and exponents are still to be evaluated experimentally. However, the analytical
models are built using the first principles and basic properties of materials and these models perform well over
a wide range of process variables. In order to develop such models in metal cutting, deformations at the
primary shear zone, tool-chip interface (secondary deformation zone) and tool-work interface (tertiary
deformation zone) must be understood in terms of tool geometry, cutting conditions and material properties.
Also considerable in-depth knowledge about the cutting mechanics and fairly high-level of mathematical
ability are necessary to model the deformation behavior in these zones. In case of micro-cutting, effect of edge
radius and material strengthening due to strain gradient have to be modeled. The analytical models also require
validation using data obtained from carefully planned and meticulously carried out experiments.
From the brief outline given above and more examples to be discussed during the presentation, it will
become clear that the researchers must delve into the depth rather than just hover at the surface level. It is
hoped that ‘snorkeling and scuba diving’ included in the title will be taken in the right spirit, as the intention is
to bring out the comparison between surface and in-depth knowledge.
Disclaimer: The details presented and discussed are from author’ s own experience spanning nearly 40 years of
teaching-cum-research career. Many examples have emerged during the discussion on different aspects of
machining with research scholars and also with undergraduate/postgraduate students inside and outside the
class rooms. Any resemblance to any part or whole of the work carried out by other researchers is only a
coincidence. The intention of this presentation is not to criticize, but to sensitise the young researchers to
nuances of machining research through illustrative examples.
Invited Talk-12
Professor Satish V. Kailas
Indian Institute of Science, Bangalore 560 012
IMPROVING MANUFACTURING EFFICIENCY THROUGH UNDERSTANDING
FRICTION IN METAL FORMING
When any material is plastically deformed the friction between the die and the work-piece is important
in deciding the direction of metal flow and this in-turn decides the strain, strain rate and temperature rise in the
work-piece. It is the strain rate and temperature of the work-piece that decides the micro-structural evolution
in the alloy being deformed. The present paper studies the role of surface roughness and the role of surface
texture in controlling the friction between the die and the work-piece. The paper also shows how much
material can be saved by proper control of this friction and also on the parameters of the surface roughness of
the die that controls this friction.
A simulation of the compression of a cylinder to form a disc is done to demonstrate how the coefficient
of friction can play an important role in the flow of the cylinder being compressed and how this will change
the shape of the deformed cylinder significantly. The compression is done using DEFORM software. In the
simulation both the top and bottom dies are split into four quadrants. The friction in these quadrants is
changed and the flow that occurs in the die, which will manifest in the shape of the deformed cylinder is
studied. Figure 1 shows the results from the various simulations. In figure 1 (a), the friction in all the four
quadrants are kept the same at 0.65. The cylinder compresses into a circular flat. In figure 2 (a), the friction in
the top two quadrants are kept at 0.1 and the bottom two are kept at 0.9. Here it can be seen that the flow is
more in the region where the friction is lower. The cylinder no longer in in the shape of a circle and is skewed.
If the friction is changed in such a way that the friction in the opposite quadrants are the same, but, 0.1 and 0.9,
it gives a completely different shape. Clearly if the friction is different in any of the quadrants the shape will
move away from circular and more machining that is required will result in more material loss and additional
machining being needed to get a disc of required dimensions.
How can one control this friction? Is the range of friction taken from 0.1 to 0.9 in the simulation
realistic? The work carried out by us has shown that the friction is controlled more by the nature of the surface
roughness and that this nature of surface roughness also controls the transfer layer of the softer deforming
metal on to the die. The experiments were conducted by rubbing pins
Figure 1(a)Figure 1(b)
Figure 1 (c)
Figure 1: The effect of friction in material flow when compressing a cylinder
made from various materials against a harder steel surface with varying nature of surface roughness. The
experimental results are shown in figure 2. The friction, depending on the material being deformed, can vary
significantly and is highest for a particular kind of surface roughness. The details of these will be discussed in
the presentation.
Figure 2: Variation of coefficient of friction on various surface finishes and materials
Invited Talk-13
Professor Raghu Echempati
Professor of Mechanical Engineering
Kettering University
Flint, MI – 48504 (USA)
[email protected]
REAL AND VIRTUAL DESIGN & MANUFACTURING IN EDUCATION AND IN
INDUSTRY
In this talk, some of the real life applications in the design and manufacturing areas will be discussed.
Advanced CAE tools and applied statistics play an important role in this area. The “ Build and break” approach
used in the past is systematically reduced due to advances in better understanding of the physics and the
underlying theoretical aspects of a process. Mathematical modeling and numerical computational tools have
been embedded in most CAE software, which in turn built confidence in accepting the results from CAE
solvers. However, building virtual prototypes is still far from reality for predicting the behavior of complex
systems such as those used in design simulation and manufacturing areas. Virtual prototypes still help in
gaining some insights of the uncertainties of the behavior of a system and the complex processes. Together
with today’ s high-speed communication tools such as Internet, CAE tools help in reducing the costs and time
associated with building the real prototypes. Advances in measurements and testing used in real life situations
close the gaps between the CAE results and the experiments. All this means that the design and manufacturing
which were based on “ Art” alone are being replaced by “ Science” . Many answers to the “ Why” and “ How” of
engineering can perhaps be answered by inculcating an interest and developing a strong background in STEM
education.
As mentioned above, some of the case studies in the design and manufacturing areas will be discussed.
These include applications of design of experiments (DOE) and response surface methodologies (RSM) to (a)
the design of a car truck stand used in repair of rail road cars, (b) machine tool vibrations, (c) modeling and
analysis of coil winding machine, and (d) metal forming. Other applications in the design and manufacturing
will also be discussed.
Invited Talk-14
Professor B. Bhattacharyya
Department of Production Engineering
Jadavpur University, Kolkata- 700 032
Email:[email protected]
ELECTROCHEMICAL MICRO MACHINING: CHALLENGES AND
OPPORTUNITIES
In non-conventional machining processes, Electrochemical Machining (ECM) has tremendous potential
on account of versatility of its applications and it is expected that it will be one of the promising, successful
and commercially utilized machining processes in the modern manufacturing industries. ECM now play an
important role in the manufacturing of a variety of parts ranging from machining of complicated, shaped large
metallic pieces to opening of windows in silicon that are a few microns in diameter. The machining of
materials on micrometer and sub micrometer scales is considered to be a key of future technology.
Electrochemical machining process is applied to micro range of applications for the production of miniaturized
parts with high precision; it is called Electrochemical Micro-Machining (EMM). EMM is an effective method
of producing variety of micro components for the aerospace, automotive, defense, electronic and biomedical
industries.
Research achievements and industrial applications have been presented in micro and nanoscale
machining using EMM. Results of recent research indicate the applications of electrochemical metal removal
in micro and nano-machining offers many opportunities that have been unexplored till now. Further research
activities in the area of EMM for effective utilization in micro and nano-fabrication require improvements in
micro-tool design and development, monitoring and control of the inter electrode gap, control of material
removal and accuracy, efficient power supply, elimination of micro sparks in inter electrode gap (IEG) and
selection of suitable electrolyte which are expected to enhance the applications of EMM technology in modern
manufacturing industries engage in ultra precision machining. Extensive research efforts and continuing
advancements in this area will make the process more efficient and effective.
A successful attempt has been reported on the development of an EMM setup for carrying out in depth
independent research for achieving satisfactory control of electrochemical machining process parameters to
meet the micromachining requirements. The developed EMM setup mainly consists of various subcomponents and systems, e.g., mechanical machining unit, microtooling system, electrical power and
controlling system, controlled electrolyte flow system and microtool feed control system etc. All these system
components are integrated in such a way that the developed EMM system setup will be capable of performing
basic and fundamental research in the area of EMM for fulfilling the requirements of micromachining
objectives.
Basic features of microtool generation utilizing EMM are explained. Good quality micro tools with different
shapes can be fabricated by controlling a proper diffusion layer thickness within a very short time utilizing
EMM. Sharp conical shape of microtool fabricated by EMM at 1.5V exhibits the unit capabilities of EMM.
Different shapes of the microtool can also be generated by EMM. Disc type tool with disc diameter 175µm,
neck diameter 93µm, neck height 815µm and disc height 70µm has been successfully fabricated by EMM.
Micro tool fabricated at three steps. Diameter reduced to 150 mm cylindrical in first step from 300 mm. Then,
again reduced to 37µm cylindrical followed by third step reduction in low voltage for conical shape generation
having tip angle 26o. This type of tools is suitable from rigidity point of view as bending stress will be less.
The taper less drilled holes of 148 µm, 140 m and 135 µm at 7 MHz, 8 MHz and 9 MHz respectively
have been successfully fabricated during drilling operation. Time of sinking at optimum feed rate were 5 min
41 sec, 7 min 15 sec and 10 min at 7 MHz, 8 MHz and 9 MHz respectively. The optimum feed rate means
maximum feed rate without short circuit between tool and work piece. Machining has been improved utilizing
higher pulse frequency.
The accuracy in terms of overcut and taper angle of micro features is important. In this area of
accuracy, microtool insulation will also play an important role. However, it is very difficult to insulate
micotool with different existing techniques. There is a need of developing insulation technique of microtool
which may improve the machining accuracy. Very small microhole with minimum overcut has been generated
by developed sharp conical shaped microtool with 150µm long and 12 µm uniform diameter at the tip. It is
important to develop the EMM process in such a manner that it improves the reliability and repeatability of the
micromachining technology. Taper less micro holes of 24 micron average diameters and micro nozzle with
taper angel, 21.58 degree, inlet diameter, 98 micron and exit diameters 51 micron have successfully fabricated
on stainless steel sheet by EMM.
Piezo-electric transducer (PZT) can be used for vibrating micro-tools, which creates acoustic waves
and cavitation in narrow IEG and improves the circulation of electrolyte that may result in reduction or
elimination of micro-spark generation. The influence of micro-tool vibration frequencies on accuracy during
EMM operation has been demonstrated. Attention to be needed in the area of dynamic gap measurement and
monitoring of IEG for better control of machining rate and accuracy. Most of the micro machining techniques
are not suitable to fabricate three dimensional (3D) shapes because of poor machining control in the Z axis.
EMM, where work material is removed by controlled anodic dissolution offers an effective solution to the
problem of machining 3D features. Layer by layer machining utilizing bottom tip of the micro tool with a
small tool feed for one layer can be considered for tool path generation. 3D microstructure with high aspect
ratio can be generated by this scanning layer-by-layer method.
Electrochemical Micro-Machining appears to be very promising as a future micro and nano machining
technique since in many areas of applications it offers several advantages. A review is presented on current
research, development and industrial practice of micro-EMM for micro and nano fabrication. New
developments in the area of electrochemical micro-machining e.g. micro-electrochemical milling, wire-ECM,
solid electrochemical machining and surface structuring etc. have also been reported. Future challenges in the
area of utilization of anodic dissolution method for manufacturing of micro and nano range products are also
highlighted. With the aid of Scanning Probe Microscope (SPM), electrochemical reactions can be confined to
the very narrow-down region due to depletion of electrolyte in the tip-surface gap. Using STM based EMM
micro-grooves with sub micron width can be fabricated with machining precision below 100 nm.
The electrochemical micro machining can effectively be used for high precision machining operations.
Extensive research efforts and continuing advancements in this area will make the process more efficient and
effective. The increasing demands for precision manufacturing of microparts and nano-features for biomedical
components, automotive components and IT applications will lead modern manufacturing engineers to utilize
EMM technique more successfully considering its advantages. Electrochemical micro-machining will be more
popular in the near future in the area of micro and nano fabrication due to its quality, productivity and
ultimately cost effectiveness.
Invited Talk-15
Professor S.K. Mukhopadhyay
CA-30, Sector-1, Salt Lake
Kolkata: 700064
ON SOME ASPECTS OF REVERSE LOGISTICS MATURITY SYNDROME
(An excerpt from the Invited talk delivered at AIMTR Conference IIT Guwahati)
(Adapted from the research paper published by author in the 47th CIRP CMS)
This research proposes a Reverse Supply Chain Maturity Model (RSCMM). Existing maturity models
for supply chains are analyzed and gaps are identified with respect to reverse supply chain. A comparison of
performance criteria between Forward and Reverse Supply Chains helps identify the broad level focused areas
for a reverse supply chain maturity model. The broad level- focus areas are analyzed in details to identify
various criteria and characteristics which act as building blocks of the maturity model. The two broad level
focused areas are: (1) Product Recovery Strategies (PRS) and (2) Recovered Product Treatment Alternatives
(RPA). Individual maturity model is proposed as per focused areas. The maturity of recovery process is
modeled through PRS Maturity and Product Treatment Process Maturity. Measurement of process maturity is
proposed through reverse supply chain metrics and Index. These are introduced to provide guidance to the
maturity model and to help improve performances overtime. The RSCMM Index is proposed to be calculated
using additive Multi Attribute Utility Theory (MAUT). RSCMM index is an indicator of sustainability and
performance of the reverse supply chain.
Deteriorating condition of environment has accentuated industries to run the business more responsibly
and sustainably. Reverse supply chain is one of the key aspects to improve this condition. As reverse supply
chain becomes strategically more important its process maturity assumes significance. The researchers also
described a reverse supply chain as “ the series of activities to retrieve a used product from a customer and
either dispose it or reuse it” . Traditionally, both academics and practitioners have concentrated on the forward
supply chain resulting in various improvement models and measuring techniques. But with improved balance
sheets through product recovery and recycling, companies are giving more importance to reverse supply chain
and altruistic reasons have made reverse logistics significantly important. According to McCormack (2001)
the Supply Chain Management (SCM) journey is a difficult one, and “ without a map and a compass, it is
impossible to manage” . These points to the need of a supply chain maturity model to improve performance.
Though there are many forward supply chain maturity models, there is a definite lack of reverse supply chain
maturity model and is clearly identified as a necessity and is described as a strategic planning model for
Reverse Supply Chain. Environmental regulations, aftermarket service, reduced manufacturing cost.
Importance of Maturity Models
The concept of process maturity proposes that a process has a lifecycle that is assessed by the extent, to
which the process is explicitly defined, managed, measured, and controlled. It is construed that the criteria of
measuring the supply chain performances in terms of maturity is different for forward and reverse supply
chains. While forward supply chain is about cost efficiency, timeliness, demand fulfilment, partner satisfaction
with customer as the ultimate goal whereas in reverse supply chain it is more about product recovery
opportunity and acquisition, reuses of recovered products, remanufacturing, recycling, disposal and
remarketing. There are some common traits and criteria as well such as logistics factors like truck loads, route
planning and various entity integration aspects that are same across reverse and forward supply chain. The
maturity models of forward supply chain are well established. A forward supply chain deals with the criteria of
supply chain integration, responsiveness, demand and supply management along with strategic intent and it
also considers Sourcing, Making, New Product, Planning and Returns as the dimensions of supply chain
maturity. The researchers also explored the forward supply chain maturity model while considering the esupply chain and outsourcing. As forward supply chain maturity models is not applicable for reverse supply
chain, it was important to first develop the focused areas of reverse supply chain which can then be further
explored for a maturity model and which is discussed in the complete text.
Reference
McCormack, K. Supply chain maturity assessment: A roadmap for building the extended supply chain. Supply
Chain Practice 2001, 4,4-18.
Invited Talk-16
Dr. Pulak M. Pandey
Associate Professor,
Mechanical Engineering Department, IIT Delhi
ON THE STRENGTH, ACCURACY AND SURFACE QUALITY OF LASER BASED
ADDITIVE MANUFACTURED PARTS
Parts are produced by layer by layer addition of material in additive manufacturing or rapid prototyping
(RP). Parts produced by RP are inferior in terms of strength, surface finish and accuracy as compared to parts
produced by injection molding or closed die forging. The strength of the rapid prototypes depends on the
bonding strength between any two layers as well as on the porosity. The strength of the polymer prototypes
fabricated by direct plastic laser sintering (DPLS) process has found to be dependant on delay time which
depends on the laser scan paths while scanning with laser. Therefore, the strength of prototypes can be
improved by using powders of multi-materials and presently trails are going on to sinter nano-clay and
polymer powder in case of DPLS process. There is also a possibility to extend this idea to design and fabricate
functionally graded materials.
The dimensional and form accuracy of rapid prototypes is mainly dependent on tessellation and slicing
during data preparation and then on shrinkage compensation while deposition. The shrinkage is quite high in
polymers as compared to metals, and during deposition, polymer shrinks in three stages, i.e., during
polymerization, during crystallization and densification if polymers in powder form is sintered. It has been
established in our laboratory at IIT Delhi that shrinkage in case of DPLS process does not remain constant but
is a function of process parameters and also depends on part geometry. A novel shrinkage compensation
method has also been developed and dimensional and form accuracy of parts processed by DPLS has been
improved. Recently, the concept of variable shrinkage at different volumes of the parts has been employed in
additive manufacturing technology but not at dexel levels.
Inferior surface quality of rapid prototypes is mainly due to stair-steeping effect, which cannot be
avoided in layer deposition processes. However a proper modeling of surface roughness as a function of
process and geometrical parameters can be done for various RP processes and the developed surface roughness
models can be used to control the surface roughness at functionally important surfaces by adaptive slicing the
CAD model and by deciding an optimum part deposition orientation. The concept has yet to be brought into
reality by the additive manufacturing machine manufacturers although few RP machines are recently
developed where the sintering is performed after spreading more than one layer of powder.
In adaptive slicing, layers of different slice thicknesses are calculated based on better surface quality or
smaller build time requirements. Many adaptive slicing algorithms have been proposed in literature however
real development of such machine which is capable of depositing slices of variable slice thicknesses requires
use of adaptive process parameters with the change in slice thicknesses. Development of theoretical models
and hardware for development of such RP machine may be considered as future research direction of our
laboratory.
Biomedical application is one of the interesting application areas of additive manufacturing. Using the
technology, a clubfoot orthosis and a clubfoot measurement device has been developed and case studies are
carried out to prove the efficacy of the developed medical devices. The talk focuses on details of all above
aspects of laser based additive manufacturing.
Invited Talk-17
Dr. R. Balasubramaniam
Bhabha Atomic Research centre, Mumbai-400085, India
E-mail: [email protected]
DIAMOND TURN MACHINING AND ITS APPLICATIONS
INTRODUCTION
Ultraprecision machined components with very close size and form controls are extensively used in
many strategic areas and for general applications. Components manufactured from metals, alloys, semi
conductor and crystals with very high level of surface quality are used as mirrors for different applications
ranging from astronomical telescope mirrors, solar panels of satellites, night vision camera to photo copying
machine drum. Traditionally, such surfaces were generated by various processes like CNC machining followed
by random finishing processes including lapping, polishing, etc. Brittle materials like glass, silicon, etc., are
amenable to loose abrasive based finishing processes, whereas, ductile materials like aluminium, copper,
nickel, etc., are generally not amenable for abrasive based finishing processes. Moreover, the cycle time for
finishing by such process is extremely large and also they are not suitable for finishing complex shapes.
Development of Diamond Turn Machining (DTM) process has overcome many of these constraints. DTM
employs the concept of using ultra high precision machine with a metrology frame of few tens of cubic nm
along with ultra sharp single crystal diamond cutting tools for machining. Since material removal is carried out
with few micron to few nm uncut chip thicknesses in DTM, classical metal cutting theory is no more
applicable to this class of machining process and thus it has opened up new areas of research. Further, this has
resulted in a paradigm shift in precision manufacturing leading to the development of a large number of
associated technologies for machine building, machining and metrology.
DIAMOND TURN MACHINE
To realize the twin objectives of obtaining high level of size & shape accuracy as well as surface quality,
number of technologies are used in building DTM machines; to name a few - aerostatic bearings for spindles,
hydrostatic bearings for tables, linear scale or laser based positioning and feedback system, vibration isolators,
high stiffness tool post, single crystal diamond tools and on-machine tool setting. The level of accuracy of the
DTM metrology frame is much more than that of the presently available co-ordinate measuring machines
(CMM). A typical DTM has spindle run-out accuracy of 30nm and positional accuracy of 10nm whereas, the
positional accuracy of best known CMM is around 250 nm. Based on their functionality, major systems of
DTM are grouped as follows.
- Machine Support System
- Spindle system
- Positioning & feed back systems
- Tool holding system
- Tool measurement system
- Machine Control system
MATERIAL REMOVAL MECHANISM
Even though the material removal mechanism appears to be similar in ultra precision machining for
generating optical quality surfaces, many of the concepts applicable for bulk material removal no longer stand
good. Unlike bulk material removal processes where unit material removal is in millimeter or few tens of
microns, DTM processes need processing unit in atomic bit size or few micron range. When such small
processing units are used, the resisting shear stress or specific shearing energy becomes extremely large. DTM
generates sub micron to few micron thickness of chip which corresponds to breakage initiation at the movable
dislocations in the crystal grains where the mean distribution intervals of movable dislocations are about one
micron. In the crystal grain of brittle ceramics, breakdown occurs due to micro crack defects which are also
distributed at a mean interval of about one micron. For processing units larger than 10 micron, break down of
ductile metals due to shear slip begins at a weak point at a grain boundary or cavity. This necessitates the tool
to withstand the specific shear energy of 103 –102 J/cm3. Conventional tool materials do not withstand such
cutting conditions and wear quickly. However, single crystal diamond tools and abrasives can withstand and
perform chip removal under such cutting conditions.
TOOLS FOR DTM
The generation of optical quality surfaces with high degree of form accuracy and surface finish depends
on three major factors viz. accuracy and rigidity of the machine, dynamics of machining and quality of the
cutting tool. Present day DTM machines have metrology frame better than 100 cu. nm. The dynamics of the
machining depends on various factors like fixtures, machining parameters, etc., and it requires in depth
understanding of the process. The inaccuracy of the tool is directly reflected on the component; when
extremely accurate and rigid machines are used with better process control, inaccuracies of the tool
significantly affect the quality of the surface generated. Hence, factors like quality of the tool, its ability to
retain sharpness over a long period of time, its interaction with the work piece material and tool setting
accuracy need special attention in DTM. Typically, a single crystal diamond tool with better than 200 nm
cutting edge sharpness, controlled waviness of lesser than one micron and specific crystal orientation on the
rake face is used for machining in DTM.
APPLICATIONS
Some applications of diamond turned components are listed in Table-1. Most of them fall under the
category of optics and others are used in the areas where size and form control are the primary requirements.
Table-1 Diamond Turn machining Applications
Aspherical lenses and mirrors
Cylindrical lenses
Aluminium substrate for compact disc
Incidence mirrors for X-ray and gamma ray telescopes
Grooves on electroplated copper for optical memory disc
Special lenses and mirrors for aerospace applications
Drums of photo copying machine
Metal mirrors for laser applications
Projection TV lenses & Fresnel surfaces
Molds for lens manufacturing & Injection molds
Faceted optics
Beam integrators
Polygonal mirrors
Steering mirrors
Axicons
Aircraft cabin windows
Diode laser heat sinks
Inter- ocular lenses &Contact lenses
Diffractive optics & Off-axis
paraboloids
Missile cone
ADVANCES IN DTM
Developments in DTM include application of fast tool servo & slow tool servo for micro nano pattern
generation and to generate complicated 3-dimensional free form surfaces. Multi-axis DTM machines with fly
cutting is another area for generating non-axi-symmetric surfaces. Extensive research work in the area of
molecular dynamic simulation to explain the material removal mechanism is pursued by various researchers.
References
1.Myler J.K, Parker R.A and Harrison A.B High quality diamond turning, Advanced Optical Manufacturing
and Testing, SPIE, 1333, 58-79(1990) .
2.Introduction to Micromachining- Chapter-3 – “ Diamond Turn Machining", R.Balasubramaniam & V.K.Suri,
Narosa Publication, (2009).
3.Ed Paul, Chris J.Evans, Anthony Mangamelli, Michael L.McGlauflin and Robert S.Polvani Chemical aspects
of tool wear in single point diamond turning, Precision Engineering, 18/1, 4-19 (1996).
Invited Talk-18
Dr. V.K. Suri
Precision Engineering Division, BARC, Mumbai
([email protected], [email protected])
MICRO – NANO- ENGINEERING: A BARC PERSPECTIVE
Micro and Nano Engineering are two advance fields of manufacturing sciences. Their names have been
allotted on basis of scale of handling. Apart from the scale of processing there is another aspect which makes
them different than conventional or macro-engineering of manufacturing science. In case of microengineering, many other phenomena get associated with the process. Wherein, size effect is one of significant
phenomena which changes mechanics & dynamics of the process at micrometric scale. At nanometric scale,
most of materials properties change drastically. Thus, it is essential to comprehend both aspect of
manufacturing science. It is necessary towards product realisation and development in field of micro and nanodomain of application like MEMS, Micro-fluidics, Lab-on Chip and Biomedical implants, etc.
Nanotechnology needs an additional supportive engineering towards productivity oriented approach.
This supportive engineering is well known method, which is called as micro-engineering. Micro-engineering
has a wide area like micro-design, micro-machining, micro-forming, micro-joining, micro-fluidics and microtribology.
BARC has adopted a pragmatic approach in realisation of Nanotechnology in Mission Mode. Wherein,
micro-engineering was brought as a significant area. In short, nano-engineering cannot be realised without
micro-engineering. They have relation like Mount Everest (nano-engineering) and Himalaya (microengineering). Since, Mount Everest cannot be comprehended without Himalaya. Henceforth, nano-engineering
cannot be implemented without micro-engineering.
The talk would encompass three major areas which are ‘Ultra Precision Measurement’ , ‘Ultra Precision
Machining’ and ‘Product Development’ . Ultra precision Measurement is being pursued for characterisation as
well as feedback for manufacturing of highly accurate & precisely micro & nano featured components. It is
essential to the devices which belong to micro fluidics, Lab on Chip, Opto-Mechanical Sensors, High speed
bearing, Biomedical devices, etc. The metrological equipment used are Universal Measuring Machines
(UMM) for shape & size measurement, Form-Taly Surf profilometer for 2D as well as 3D texture &
topography measurement, Wave front sensing based metrology, and coherent correlation interferometer (CCI)
for nano & sub-nano finished components.
Ultra Precision Machining includes Nano-regime machining through Diamond Turn Machining (DTM)
route, Laser Lithography, Non-conventional micro-machining using ‘Photo Chemical Machining, MicroEDM, Micro-wire EDM, Micro-ECM, Micro-turning, Micro-milling, Micro-drilling & hybrid Micromachining processes’ , Nanofinishing using electrolytic in dress grinding (ELID) to maintain surface finish in
order of few tens of nanometer and Nanofinishing using a hybrid finishing process which is named as CMMRF
for atomistic surface generation.
Product Development has a wide range of activities towards development of devices which are
developed for DAE as well as society. The devices are High speed bearings, Heavy water sieve trays, micronozzles, Nano-delivery pin, Micro-heat exchanger, Micro-chemical reactor, metallic & nano-metallic mirrors,
MEMS based pressure sensors ranging from 0 to 600bar, Optomechanical pressure sensor, Optomechanical
vacuum cell, Optomechanical temperature sensor, art work to product development using PCM process for
preservation of Traditional Arts and creation of employment potential for Rural Artisans.
Invited Talk-19
Professor Satyandra K. Gupta
Advanced Manufacturing Lab
Maryland Robotics Center
University of Maryland, College Park
TOWARDS AUTOMATED MANUFACTURING OF GEOMETRICALLY-COMPLEX
HETEROGENEOUS STRUCTURES
Biological creatures often utilize geometrically-complex heterogeneous structures to exhibit remarkable
capabilities. The geometric complexity arises due the large number of features in the structure and the
underlying shape complexity of the individual features. The heterogeneity manifests itself at multiple size
scales due to the use of multiple different materials. Many application areas such as robotics, bio-medical
devices, thermal management systems, and aerospace structures can significantly benefit from utilizing
geometrically-complex heterogeneous structures. The traditional approach to manufacturing that involves
fabricating constituent components and assembling them together is not well suited to realize such structures in
a cost-effective manner. This seminar will begin by describing a new manufacturing process called in-mold
assembly. This process integrates customized mechanisms inside the mold to morph the mold cavity during the
molding operation to enable the realization of geometrically-complex heterogeneous structures. These
mechanisms are realized using 3D printing and serve the role of robots during in-mold assembly. This
automates the manufacturing operation by eliminating the need for post-molding assembly operations. The
material is assembled in the liquid state during in-mold assembly, and hence articulated heterogeneous
structures that would have been otherwise impossible to realize can be made. This process is inherently parallel
in nature, and hence a large number of assembly operations can be performed concurrently in a cost effective
manner. This process also eliminates the need for manually handling small parts and hence can also be used to
perform assembly at small size scales. Topics covered during the seminar will include thermo-mechanical
characteristics of the in-mold assembly process at macro and mesoscale and the associated process model. The
second part of the seminar will describe computational foundations for automatically designing, optimizing,
and fabricating molds to enable digital manufacturing of the desired structures from CAD models. This part
will also describe mold design solutions and manufacturability rules associated with the in-mold assembly of
polymer composite structures. The final part of the seminar will describe how in-mold assembly is being used
to realize novel bio-inspired robots, bio-medical devices, and polymer heat exchangers.
Biography: Dr. Satyandra K. Gupta is a Professor in the Department of Mechanical Engineering and the
Institute for Systems Research at the University of Maryland, College Park. He is the director of the Advanced
Manufacturing Laboratory and the Maryland Robotics Center. Prior to joining the University of Maryland, he
was a Research Scientist in the Robotics Institute at Carnegie Mellon University. He served as a program
director for the National Robotics Initiative at the National Science Foundation from September 2012 to
September 2014.
Dr. Gupta'
s interest is broadly in the area of automation. He is specifically interested in automation
problems arising in Engineering Design, Manufacturing, and Robotics. He is a fellow of the American Society
of Mechanical Engineers (ASME). He has served as an Associate Editor for IEEE Transactions on Automation
Science and Engineering, ASME Journal of Computing and Information Science in Engineering, ASME
Journal of Mechanism and Robotics, and SME Journal of Manufacturing Processes.
Dr. Gupta has received several honors and awards for his research contributions. Representative
examples include: a Young Investigator Award from the Office of Naval Research in 2000, a Robert W.
Galvin Outstanding Young Manufacturing Engineer Award from the Society of Manufacturing Engineers in
2001, a CAREER Award from the National Science Foundation in 2001, a Presidential Early Career Award for
Scientists and Engineers (PECASE) in 2001, Invention of the Year Award in Physical Science category at the
University of Maryland in 2007, Kos Ishii-Toshiba Award from ASME Design for Manufacturing and the Life
Cycle Committee in 2011, and Excellence in Research Award from ASME Computers and Information in
Engineering Division in 2013. He has also received six best paper awards at conferences and 2012 Most Cited
Paper Award from Computer Aided Design Journal.
Invited Talk-20
Professor Marc Madou
Chancellor'
s Professor
Mechanical & Aerospace Engineering and Biomedical Engineering
University of California, Irvine, CA
ELECTROMECHANICAL SPINNING (EMS) A NEW NANOMANUFACTURING
OPTION
Background:
Fabrication of functional polymeric nanofibers has attracted considerable attention from researchers in
academia and industry due to a wide variety of applications of such fibers in the fields of sensors and actuators
[1-4], energy storage [5, 6], smart textiles [7-10], optoelectronics [11, 12], tissue engineering [13-16],
prosthetics [17], drug delivery [18, 19], micro resonators [20], and piezoelectric energy generators [21].
However, widespread success of these applications is impeded by the limited capabilities of presently available
fabrication techniques to accurately control the physical properties and positioning (patterning) of the
nanofibers in a reliable and economical way. Techniques analogous to Electron-Beam Lithography (EBL) and
Dip-Pen Lithography do allow controlled writing of nanofibers but face stiff economical or technical
challenges in scale-up. Electrospinning on the other hand has emerged as a successful method to fabricate
various types of polymeric nanofibers on a large scale [22]. This technique, also known as Far-Field
Electrospinning (FFES), involves the application of a high voltage (10-15kV) to bias a polymer solution in a
syringe against a grounded substrate with the syringe tip separated from the substrate by a distance of 10 to
15cm. The grounded substrate then electrostatically pulls onto the droplet at the tip of the syringe to induce
flow of charge in the form of a polymeric jet that undergoes stretching and whipping motion in situ by the
electric field leading to the generation of nanofibers that land onto the substrate. However, FFES is hard to
control due to the electric instabilities that are inherent in the electrospinning process [23-25]. Although the
alignment of nanofibers along a preferred direction has been accomplished through the use of a rotating drum
collector [26-29], and by using electrical field manipulation [23, 30-32], precise 2D and 3D patterning is still
very difficult to achieve. Generally speaking, current state-of-the-art fabrication methods for polymeric
nanofibers fail to deliver precise, inexpensive, fast and continuous patterning capability.
Electromechanical Spinning:
A technology developed by our team that alleviates most of the listed problems is called
Electromechanical Spinning (EMS). It offers a key advance in electrostatic fabrication of functional nanofibers
by lowering of the operating voltage by several orders of magnitude and an attendant increase in patterning
control compared to FFES. The EMS technology uses a superelastic polymer based carrier ink that can be
utilized in conjunction with functional materials to pattern a range of versatile nanofibers with desired
properties. Figure 1 shows a schematic of our setup with the perturbation free polymeric jet emanating out of
the Taylor cone to generate nanofibers by electro-mechanical stretching. These nanofibers are generated
continuously and targeted with precision on 2D or 3D substrates. 3D micropost arrays were wired together
with the electrospun nanofibers as shown in Figure 2. The major difference between FFES and EMS
technology is the ability to tightly control bending instabilities as demonstrated in Figure 3, which is found to
be enabled by the low operating voltage and the viscoelastic properties of the carrier ink. The ability to operate
in the low voltage regime also improves control over thickness of the nanofibers directly by controlling the
applied voltage and can be further fine-tuned by relative stage speed with respect to the nozzle as evidenced in
Figure 4. We have successfully demonstrated patterning of nanofibers across a wide range of diameters from a
few microns to sub 20nm. Preliminary results were published in the April 2011 [33] issue of Nano Letters.
In this contribution we will detail the work reported there and additional results obtained from 2011 to
2014.
References
1. Liu, H., et al., Polymeric nanowire chemical sensor. Nano Lett, 2004. 4(4): p. 671-675.
2. Hahm, J. and C.M. Lieber, Direct ultrasensitive electrical detection of DNA and DNA sequence variations
using nanowire nanosensors. Nano Lett, 2004. 4(1): p. 51.
3. Kameoka, J., et al., Fabrication of Suspended Silica Glass Nanofibers from Polymeric Materials Using a
Scanned Electrospinning Source. Nano Letters, 2004. 4(11): p. 2105-2108.
4. Wang, M.C.P. and B.D. Gates, Directed assembly of nanowires. Materials Today, 2009. 12(5): p. 34-43.
5. YUN, K., et al., A LITHIUM SECONDARY BATTERY COMPRISING A SUPER FINE FIBROUS
POLYMER ELECTROLYTE AND ITS FABRICATION METHOD. 2001, WO Patent WO/2001/089,023.
6. Choi, S.W., et al., An Electrospun Poly(vinylidene fluoride) Nanofibrous Membrane and Its Battery
Applications. Advanced Materials, 2003. 15(23): p. 2027-2032.
7. Ro ek, Z., et al., Potential applications of nanofiber textile covered by carbon coatings. Journal of
Achievements in Materials and Manufacturing Engineering, 2008. 27(1): p. 35-38.
8. Pant, H., et al., Electrospun nylon-6 spider-net like nanofiber mat containing TiO2 nanoparticles: a
multifunctional nanocomposite textile material. Journal of Hazardous Materials, 2010. 185(1): p. 7.
9. Lee, S. and S. Obendorf, Use of electrospun nanofiber web for protective textile materials as barriers to
liquid penetration. Textile Research Journal, 2007. 77(9): p. 696.
10. Gibson, P., H. Schreuder-Gibson, and D. Rivin, Transport properties of porous membranes based on
electrospun nanofibers. Colloids and Surfaces A: Physicochemical and Engineering Aspects, 2001. 187188: p. 469-481.
11. Di Benedetto, F., et al., Patterning of light-emitting conjugated polymer nanofibres. Nat Nano, 2008.
3(10): p. 614-619.
12. Pagliara, S., et al., Hierarchical assembly of light-emitting polymer nanofibers in helical morphologies.
Applied Physics Letters, 2009. 95(26): p. 263301-3.
13. Jin, H.-J., et al., Human bone marrow stromal cell responses on electrospun silk fibroin mats.
Biomaterials, 2004. 25(6): p. 1039-1047.
14. Mo, X.M., et al., Electrospun P(LLA-CL) nanofiber: a biomimetic extracellular matrix for smooth muscle
cell and endothelial cell proliferation. Biomaterials, 2004. 25(10): p. 1883-1890.
15. Yoshimoto, H., et al., A biodegradable nanofiber scaffold by electrospinning and its potential for bone
tissue engineering. Biomaterials, 2003. 24(12): p. 2077-2082.
16. Li, W.-J., et al., Electrospun nanofibrous structure: A novel scaffold for tissue engineering. Journal of
Biomedical Materials Research, 2002. 60(4): p. 613-621.
17. Nguyen Vu, T., et al., Vertically aligned carbon nanofiber arrays: an advance toward electrical–neural
interfaces. Small, 2006. 2(1): p. 89-94.
18. Luu, Y., et al., Development of a nanostructured DNA delivery scaffold via electrospinning of PLGA and
PLA-PEG block copolymers. Journal of Controlled Release, 2003. 89(2): p. 341-353.
19. Zeng, J., et al., Biodegradable electrospun fibers for drug delivery. Journal of Controlled Release, 2003.
92(3): p. 227-231.
20. Zande, A.M.v.d., et al., Large-Scale Arrays of Single-Layer Graphene Resonators. Nano Letters, 2010.
10(12): p. 4869-4873.
21. Chang, C., et al., Direct-Write Piezoelectric Polymeric Nanogenerator with High Energy Conversion
Efficiency. Nano Letters, 2010. 10(2): p. 726-731.
22. Reneker, D.H., et al., Electrospinning of Nanofibers from Polymer Solutions and Melts, in Advances in
Applied Mechanics, A. Hassan and G. Erik van der, Editors. 2007, Elsevier. p. 43-195, 345-346.
23. Li, D., Y. Wang, and Y. Xia, Electrospinning of polymeric and ceramic nanofibers as uniaxially aligned
arrays. Nano Letters, 2003. 3(8): p. 1167-1171.
24. Doshi, J. and D. Reneker, Electrospinning process and applications of electrospun fibers. Journal of
Electrostatics, 1995. 35(2-3): p. 151-160.
25. Yu, J. and G. Rutledge, Electrospinning, in Encyclopedia of Polymer Science and Technology, H.F. Mark,
Editor. 2007, John Wiley & Sons: New Jersey.
26. Matthews, J.A., et al., Electrospinning of Collagen Nanofibers. Biomacromolecules, 2002. 3(2): p. 232238.
27. Katta, P., et al., Continuous Electrospinning of Aligned Polymer Nanofibers onto a Wire Drum Collector.
Nano Letters, 2004. 4(11): p. 2215-2218.
28. Kim, K., et al., The effect of molecular weight and the linear velocity of drum surface on the properties of
electrospun poly (ethylene terephthalate) nonwovens. Fibers and Polymers, 2004. 5(2): p. 122-127.
29. Wannatong, L., A. Sirivat, and P. Supaphol, Effects of solvents on electrospun polymeric fibers:
preliminary study on polystyrene. Polymer International, 2004. 53(11): p. 1851-1859.
30. Teo, W. and S. Ramakrishna, Electrospun fibre bundle made of aligned nanofibres over two fixed points.
Nanotechnology, 2005. 16: p. 1878.
31. Theron, A., E. Zussman, and A. Yarin, Electrostatic field-assisted alignment of electrospun nanofibres.
Nanotechnology, 2001. 12: p. 384.
32. Kessick, R., J. Fenn, and G. Tepper, The use of AC potentials in electrospraying and electrospinning
processes. Polymer, 2004. 45(9): p. 2981-2984.
33. Bisht, G.S., et al., Controlled Continuous Patterning of Polymeric Nanofibers on Three-Dimensional
Substrates Using Low-Voltage Near-Field Electrospinning. Nano Letters, 2011.
Invited Talk-21
Professor Shiv G. Kapoor
Grayce Wicall Gauthier Chair
Mechanical Science and Engineering
University of Illinois at Urbana-Champaign
METALWORKING FLUID MANAGEMENT FOR SUSTAINABLE
MANUFACTURING
Metalworking Fluids are widely used to facilitate machining by providing heat removal, lubrication, rust
inhibition, and chip evacuation. The trend towards higher velocity machining is placing even greater demands
on MWF. While the benefits of MWF use are clear from a machining perspective, the employment of MWF is
a double-edged sword bringing with its benefits a host of problems. Three problematic issues including
economic, health & safety impacts and environmental footprint are associated with the use and disposal of
metalworking fluids. MWF are reported to contribute as much as 8-16% of the machining costs. These include
acquisition, maintenance, energy use, and equipment related costs. Significant concerns are emerging as to the
adverse health effects associated with chronic exposure to MWF. Over 10 million industrial workers are
estimated exposed to MWF via inhalation, skin absorption or both. It is estimated that the total volume of
MWF being disposed annually is at least 2 billion gallons in the USA, spread across thousands of small
facilities. Additives used in MWF formulations create additional wastewater processing problems such as
lowered efficiency of heavy metals precipitation, increased foam and oil emulsification. If unaddressed, both
the economic as well as attendant health and safety risks associated with MWF are expected to impose a
significant burden on this sector impacting its competitiveness.
Increased interest has been bought to bear on dry machining world-wide over the last decade. The dry
machining, however, exacerbates issues related to cutting process quality, efficiency, and economics, and for
these reasons dry machining has been only limited adoption. While research on “ minimum quality lubrication
(MQL)” has demonstrated the ability to successfully reduce MWF quantities in a given application, the
treatment and health-related issues, especially misting, remain on the table. There are an exciting range of
technical innovations that address the shortcomings in current MWF formulations as well their application and
management. These innovations span a wide range such as restructured supply chain relationships, improved
product formulations, advanced separation technologies, incorporations of decision-making models for product
choice and optimization. However, a few of these innovative practices have gained a foothold in industrial
practice for a variety of reasons; primary among them is the uncertainty associated with the changes to normal
practice and the impact of these changes to manufacturing quality, machine tool life, and health and safety.
More recently, the focus has been in creating enabling infrastructure on monitoring and management of MWF
to ensure that innovations are embraced by management and readily accepted at the plant floor. Two such
innovations are discussed here and their impact on sustainability has been described.
Microfiltartion of Metalworking Fluids
Technologies such as conventional cartridge filtration, coalescers, and centrifugation, are used for
extending the working life of metalworking fluids. These technologies are limited in their capability to remove
particulate matter less than 10 µm, emulsified oil extraneous to native emulsion (also called tramp oil) and
bacterial contamination. This has spurred interest in developing more effective technologies for dealing
simultaneously with multiple contaminants in MWF. One technology that is seeing increased use to reduce
negative MWF impacts is in-process microfiltration, a membrane-based technology that uses physical
separation to remove unwanted contaminants. By filtering out contaminants while the fluid remains in use, the
life of the fluid is extended and the environmental impact and disposal costs are reduced due to the smaller
volume of toxic effluent. Microfiltration has currently been adapted in industry for recycling synthetic MWFs.
However, in case of semi-synthetic MWFs the membrane pores of a microfilter are fouled not just by
contaminants, as with the synthetic fluids, but also by the semi-synthetic fluid components (native oil
emulsions/particles) themselves. Moreover, fouling, the obstructing of pores by fluid material causes the
membranes to lose effectiveness as MWF transmission through the membrane decreases. Fouling of
membranes is the primary obstacle remaining to overcome before microfiltration can gain industry acceptance
and thereby further sustainable manufacturing techniques.
A fouled membrane can be cleaned to increase the flux of MWF, however, surfactant cleaning only helps
to remove deposited particles from the top of the membrane and adsorptive pore constriction on the interior of
the membrane. The best approach for reducing fouling in microfilters is to redesign the filters themselves to
discourage fouling. Some investigative studies into the behavior of MWF components (native oil particles) and
their effect on fouling in the microfilter have been conducted. A fluid dynamic model of the membrane
tortuous pore geometry is used to simulate the progression of fouling and the associated effect on flux decline.
It has been shown that low flux decline is associated with relatively low transmembrane pressures and nearzero values of Particle-particle (PP) - and Particle-membrane zeta potential; and relatively high transmembrane
pressures and large negative values of zeta potential. Fouling is observed to initiate with partial pore blocking
followed by cake layer development. The simulation results suggest the possibility of reducing flux decline by
applying electrostatic forces to certain locations of the microfilter, instead of to its entirety and utilize a hybrid
filter to improve the flux decline.
Machining of Titanium Using an Atomization-Based Cutting Fluid Application System
Titanium is a unique engineering material that has been applied for decades in a number of critical areas
including structural components in aircraft and a variety of medical implants. However, machining this
material is still a vital issue in terms of tool life, which greatly impacts overall production cost. During
titanium machining, highly localized intensive heat is produced at the tool-workpiece interface that cannot
dissipate rapidly because of very poor thermal conductivity of Ti. As the temperature rise is rapid and highly
localized, Ti becomes highly chemically reactive with the tool material. As a result, the tool edge suffers from
edge chipping and plastic deformation via galling and seizure of chips. In order to remove heat rapidly from
the interface, several techniques have been explored by the researchers and the manufacturers. These include:
i) minimum quantity lubrication (MQL), ii) high-pressure cooling, iii) cryogenic coolant system with liquid
nitrogen, and iv) supercritical CO2-based cutting fluid. In these techniques, the cutting fluid is sheared with
compressed air or high pressure. However, penetration of the cutting fluid may still be improved if it could be
delivered in the form of micron-scale and separated fluid droplets. Moreover, such droplets may consume a
smaller amount of cutting fluid compared to any other alternative approaches described above.
Recently, an atomization-based cutting fluid (ACF) application system where atomized droplets are first
generated from a given cutting fluid and then mixed with pressurized and controlled gas flow to direct the
droplets at the cutting zone in titanium machining is discussed. The experimental results show that such ACF
spray system can effectively reduce the cutting temperature and enhance lubricity at the tool-chip interface
compared to dry and flood cooling conditions. Another advantage of using such droplets is the tool with the
ACF spray system survived longer in terms of flank wear (above 420 s) than that with the flood cooling
condition (about 360 s). With the ACF spray, the amount of the edge chipping was also found to be less than
that with the flood cooling condition.
Conclusions
The degree of economic, environmental, and health and safety burden imposed on this sector due to the use
of metalworking fluids is high, adversely impacting long term competitiveness. There is an urgent need to
lighten this burden through a combination of fundamental research, management and worker training and
accelerating the diffusion of existing innovations to the commercial space.
Invited Talk-22
Professor Mustafizur Rahman
National University of Singapore
Singapore
MECHANICAL/MANUFACTURING ENGINEERIING FOR SUSTAINABALITY THROUGH
INNOVATON
Abstract
A prerequisite for development is growth and that is directly related to production or output of a country. If
production is done via a sustainable path it can maintain the sustainability of development. Mechanical and
Manufacturing Engineers predominantly shoulder manufacturing. As mechanical/Manufacturing engineering is
somewhat considered the “ merging ground” of all forms of engineering, the level of mechanical/manufacturing
engineering can be a reliable barometer for measuring the development in a country or economy. Thus
mechanical/manufacturing engineers play a vital role in development in countries across the globe.
Sustainable development can only be assured through sustainable manufacturing. ‘Revolutionary innovation’
is of utmost importance for a sustainable manufacturing and development. However, ‘evolutionary innovation’
is also very important to maintain sustainability.
In this paper, the main components of sustainable development that will be discussed are economic,
environmental and social sustainability (Fig. 1); what each particular sustainability means and why it is
important to work towards them, and how mechanical/manufacturing engineers play a pivotal role in
innovation to achieve sustainable manufacturing industry and in turn sustainable development.
Keywords: Mechanical/Manufacturing Engineering, Innovation, Sustainable Development
Introduction
The term sustainable development focuses attention on intergenerational equity along economic,
environmental as well as social issues. A widely accepted definition of sustainable development is –
“ development which meets the needs of the present without compromising the ability of future generations to
meet their own needs” [1]. Generally, development is considered unsustainable when insufficient attention is
paid to the environmental consequences especially.
Before elaborating further about sustainable development, it is important to establish a key point:
economists generally consider economic growth as a prerequisite for development. Economic growth on its
own does not necessarily imply development as a country may grow without any development objective being
achieved. On the other hand, development necessitates growth, as developing countries need an increase in
their total economic output to be able to afford making progress on the development front.
Sustainability is crucial so as to ensure future generations are not neglected when present-day
governmental planning and economic production is carried out. There should always be a balance whereby
needs of the present are met without jeopardizing the standard of living of the generations to come, so as to
avoid threatening their survival.
Components of sustainable development
Economic Sustainability
As mentioned earlier, the need for growth is paramount in achieving economic development and therefore
economic sustainability. Economic sustainability is defined as the use of various strategies to ensure that
existing resources are employed optimally. Th
Thee idea is to promote the use of all available resources in a way
that is both efficient and responsible, so as to yield long
long-term benefits.
Figure 1. Major components of sustainable development
Environmental Sustainability
Environmental sustainability involves making decisions and taking action that are in the interests of protecting
the natural world, with particular emphasis placed on preserving the capability
capability of the environment to support
human life in the long run.
Environmental and economic issues are inseparably interlinked and these must go hand in hand otherwise
one will be a hindrance to the other. Production meets the needs of the global population, be it capital goods or
consumer goods. However, this comes at a cost – the environment is sacrificed for every good that is
produced; deforestation is rampant and carbon emission is increasing annually. These are just some of the
examples of how the Earth is being damaged gradually.
Coupled with deforestation, the natural environment is unable to cope with the increasing levels of carbon
dioxide and other greenhouse gases. These greenhouses gases therefore create a layer around the atmosphere
and block reflected
ted heat from exiting atmosphere. Hence giving rise to global warming. Global warming has
seen the average temperature of the Earth rise substantially over the last couple of decades ((Fig. 2). The
consequential melting of glaciers for instance has caused water
water levels to rise annually, threatening the
livelihood of millions of people around the world as countries could soon be submerged.
Social Sustainability
Although a minor segment in this paper, social sustainability is just as essential in keeping a cou
country healthy
and smooth running as economic and environmental sustainability is. Administrations must balance economic
sustainability with that of social sustainability. If proper attention is not paid to a country’ s population, people
will be left behind,, and standard of living in the country will take a hit as a result. Therefore, governmental
planning has to ensure the people are not forgotten and they are appropriately taken care of, with emphasis on
provision of healthcare, education and a systematic transportation system which will in turn result in improved
levels of productivity of the country and its people.
Why is sustainable development necessary?
Firstly, whether it is an individual or corporation, sustainability is imperative to remain relevant. If a
corporation becomes irrelevant, it will fall behind the respective industry and face natural extinction.
Secondly, sustainability is necessary for survival. If a corporation does not manage its resources properly, it
will not have a sustainable model and thus, it will in time face extinction too. Thirdly, sustainability is
necessary to remain competitive in the respective industry. Hence, it can be said that to remain sustainable,
one should remain relevant to both the industry it is a participant of, and to the society it produces goods and
services for.
Relevance stems from necessity. And necessity is derived from what society desires. As such, production
should aim to be relevant to the target audience. For instance, medical inspection with minimum or no pain is
universally desired. During the 1980s, endoscopic inspection was extremely painful because the cable
connecting the camera was so large in diameter that a patient would fear having to come back for a second
inspection. From the 1990s, the system has seen much improvement, as the tube has become so slender that
patients do not feel any pain during inspection.
Figure 2. Increase in global average temperature [2]
How to achieve sustainability?
Achieving Economic Sustainability
When considering economic sustainability, attention must be paid to natural resources – the root of
majority of economic activity. For decades, corporations have extracted natural resources such as coal, crude
oil and natural gas with no consideration for the environment or the imminent impact it has on future
generations. Only recently has it been stressed that natural resources are fast depleting, and at the rate it is
going, it will not be long before essential natural resources would have been exhausted, and upcoming
generations will struggle to meet their basic needs. This therefore shows, sustainability has not been at the
forefront of governmental planning as people have been living for today, without consideration for the future.
There has to be a change in mentality amongst people and administrations, to shift their focus to achieve a
balance where both economic development and economic sustainability is achieved. Then only will we truly
see the needs of the present being met, while keeping in mind the needs of future generations.
Achieving Environmental Sustainability
Achieving environmental sustainability is an endeavor that stretches generations, keeping in mind the need to
maintain an ecological balance. Production has to be careful not to damage the environment more than it
already has, and more importantly, at a faster rate than the environment’ s ability to repair itself.
Severe environmental regulations are forcing automotive manufacturers to improve the design of fuel
injection nozzles to be smaller in size and to have improved accuracy. Fuel injection nozzles are getting finer
day-by-day to ensure better fuel efficiency. This ensures lesser carbon emission into the atmosphere.
Furthermore, reliable, clean and renewable sources of energy are key to environmental sustainability. The
need to shift focus away from coal and crude oil, and introduce solar power and wind energy for example, is a
welcomed move taken by many countries. Furthermore, the production of electric cars from large carmakers
such as Mitsubishi and Nissan is paving the way for a cleaner environment and air quality, by reducing the
dependency on petrol and diesel fuel. Thus there is a need to increase awareness and investment, so as to
increase innovation in developing technology that is able to support these renewable sources of energy and
distribute it to households on a large scale.
By keeping the health of the environment at the at the forefront of governmental planning when
considering growth and development measures, countries will pave the way for sustainability and future
generations will be able to reap the benefits of a healthy planet, good quality of life and renewable sources of
energy which will last them for generations to come.
Achieving Social Sustainability
Every government faces the tall task of satisfying the population it serves. It is important to ensure that living
standards are paid attention to by governments. This involves a continuous effort to improve town planning by
developing adequate housing, building well-connected roads and constructing an enduring public
transportation system such as the London Underground system or the New York Subway system. By providing
such essentials to the public, governments will be able to improve the standard of living in their country.
Considering the sheer volume of cars in Bangladesh’ s capital, Dhaka, an underground train service would
benefit the country greatly, eliminating the pains of traffic congestion and traffic accidents.
Another step to attain social sustainability is to ensure a balanced distribution of income, thus gradually
eradicating poverty. A widening income gap will cause social strife, and that will hamper both the social and
economic balance in a country. Therefore, it is important to ensure the poor do not get poorer while the rich get
richer. It is necessary to distribute income as equally and fairly as possible so as to improve the overall
standard of living in a country.
In one of the OPEC summits, the Prime Minister of Singapore, Mr. Lee, delivered a speech addressing the
issue of sustainability, and it is important to highlight some of his key points that are relevant to this paper:
Government will carry out the planning for sustainable development and prepare the platform –
Governments should draw the long-term national plan, set guidelines and facilitate the execution of such a
plan, by removing hurdles and bottlenecks such as any excessive legal or governmental red-tape.
Industrialists, mainly within the private sector, will execute such plans – Private sector firms should
join hands with the public sector and the government’ s planning agencies to start production facilities and
industries to generate income, wealth and prosperity.
Author would like to add – Engineers will be carrying out innovation, production and finally will carry
out productivity improvement.
Role of engineers in sustainable development
Engineers are involved in the innovation and production of goods and therefore play a vital role in ensuring
sustainable development. Without their planning and innovation, future generations will run into severe
problems.
It is important to note that Engineering is a discipline that cultivates in its students analytic and problem
solving skills essential to their profession. This skill set can be crucial if well utilized in governmental planning
to create a sustainable economy and environment. Thus, it is no surprise that 70 percent of cabinet members in
the government of Singapore are Engineers, Architects or Mathematicians, as they are trusted to plan for the
future.
Innovation has to be paid special attention to by engineers across the world. With it, there will be an
improvement in efficiency of production. This is necessary as innovative ideas such as the introduction of
battery-operated cars are a very welcomed step to a cleaner and greener environment. If engineers continue on
the path of innovation to develop relevant products needed by societies, keeping the economy and environment
in mind, the three main aspects of sustainability discussed in this paper will slowly come to fruition and the
dream of a sustainable future for the generations to come will be realized. Therefore it is imperative that
engineers continue learning the fundamental principles of their subject and embrace the skill set that comes
with it. They can then cooperate with industrialists, governments and economists to create a global impact,
whereby everyone will work towards a common goal – sustainability.
Role of mechanical/mechanical engineers in sustainable development
Having established the general role of engineers in sustainable development, it is important to now highlight
specifically, the role of mechanical engineers in sustainable development.
Mechanical engineering is apparently considered a discipline mainly designed to be dealing with machines
and mechanical systems. If we take a closer look at the roles and responsibilities of mechanical engineers, this
discipline can be considered as the merging point of all other engineering disciplines. For instance, if we think
of a machine or a manufacturing unit constructed together by a mechanical engineer, the knowledge
involvement or inputs from other disciplines are evident. Inputs are acquired from prior knowledge of other
engineering disciplines through experience and exposure, or they are obtained by seeking help from experts in
the particular engineering discipline: planning and design are formulated from the mechanical engineering
discipline; control and mechatronics systems are inputs from mechatronics engineering discipline; foundation
and infrastructure information come from civil engineering discipline; marketing and management input come
mechanical or industrial engineering discipline.
Growth of an economy mainly depends on industrial development and the backbone of industrial
development is manufacturing. The main contribution in production or manufacturing comes from mechanical
engineers. However, if mechanical engineers constantly produce goods using outdated technology and cannot
produce goods that are relevant (meet the needs and desires of society) presently, then the whole
manufacturing system will be unsustainable. For instance, Korea was once producing certain components of
the iPhone, which was the most technologically advanced phone at the time of its release. On one hand,
Korean producers became the master of the latest manufacturing technology, and they combined their
newfound expertise with innovation to become the strongest competitor of the iPhone today. China, the
assembler of the iPhone, has also started to produce their own brand of telephone products, which are almost
of the same quality or even better in some aspects as compared to the famed Apple iPhone. Unfortunately, as
USA has only been involved in design, they have lost their edge in manufacturing technology. Thus, they have
had a gradual plunge in competitiveness, which has resulted in them losing their economic supremacy, with
China breathing down their neck as the 2nd largest economy.
Thus, the main roles of engineers are:
1) Engineers need to carry out production; they need to be involved in both production planning and
financial planning. Planning without the involvement of engineers is likely to bring problems and in
most cases failure.
2) Engineers need to be actively involved in national planning for sustainable development. As mentioned
above, Singapore’ s success can be pointed at the fact that 70% of the cabinet members are engineers,
architects or mathematicians. The Prime Minister himself has a degree in Mathematics from Oxford. It
is also interesting to note that one of the past Prime Ministers of Japan was engineer from Tokyo
Institute of Technology, thus there is no questioning the positive impact engineers have on
governmental planning.
3) Engineers also need to be innovative – Innovation is the key to survive. Corporations need to remain
competitive by developing products superior to that of their competitors.
4) Developing relevant products - Application of innovative ideas allow us to remain relevant by
developing necessary products that are desired by society, or that are necessary for advancement in
standard of living.
5) Improving efficiency in production – Innovative ideas will lead us to achieve better products with high
efficiency and productivity and ultimately more economic benefit. With more efficient production
methods, resources will be better utilized, therefore making production more sustainable.
6) Tackling problems which cause ecological or health problems - Innovative ideas need to be applied to
solve ecological and health issues. For example, current automotive vehicles have two serious
problems; exhaust from the automotive engine and casting of the engines produce large amount of CO2
gas and this is damaging the environment. Therefore, the revolutionary idea of removing the engine
from cars and introducing battery-operated cars instead, is a very welcomed solution to the problem of
global warming.
Innovation
The process of translating an idea or invention into a good or service that is of value and for which customers
will pay. To be called an innovation, an idea must be replicable at an economic cost and must specify a
specific need. Innovation involves deliberate application of information, imagination and initiative in deriving
greater and/or different values from various resources.
Innovation is divided into two broad categories: ‘Revolutionary innovation’ , and ‘Evolutionary innovation’
and the author would like to describe them as follows:
1) Revolutionary Innovations – It is a break though technology and also called ‘first of its kind’ technology.
For instance, automobile, radio, television, telephone, cell phone, etc. In such items, ‘large volume –
small variety’ is the trend. However, in the same product if technology level has a leap jump, i.e., if a
revolutionary change takes place, then it is also called a ‘revolutionary innovation’ . For instance when
‘cell phones’ first came in the market it was a revolutionary innovation and the production volume was
large and the variety was small.
2) Evolutionary innovation
With the passing of time, a revolutionary innovation technology goes through ‘perfection’ and varieties in
the same product increases and each variety has smaller volume. For instance a revolutionary innovation,
‘cell phone’ went through technological perfections through evolutionary innovations and its product
varieties started to increase to meet various need of customers and the volume of each variety became
small.
However, it is interesting to note that with the passing of time, the cell phone technology had another
break through with a significant level of improvement of technology by ‘Apple’ and ‘I-Phone’ came to the
market. This product managed to integrate various technologies (weighing roughly 1400 kg) into one
product (weighing only 200 gm). So this innovation is also a ‘revolutionary innovation’ .
(a)
(b)
Figure 3 Examples of (a) Revolutionary and (b) Evolutionary Innovations
Mechanical/Manufacturing engineering curriculum
Mechanical engineers need to adopt sustainable manufacturing. There has to be emphasis on teaching
innovation so as to bring about sustainability. Innovation will help in problem solving and development of
relevant goods, as mentioned earlier. To solve a problem one should be able to first analyze the problem, and
then be able apply the fundamental knowledge learned, to solve it. Of course, there is a need to be creative
when it comes to problem solving. Thinking out of the box is something that can be encouraged and nurtured
in students, so that they may be creative and innovative when tackling problems.
Thus, engineering students should learn:
1) The fundamentals of engineering
2) Applications of the fundamentals
3) How to become creative or innovate
4) How to manage for sustainable development
5) How to plan for sustainable development
How should all these be nurtured?
1) Strong emphasis should be placed on design and fabrication technology:
Students should be taught and trained in design starting from conceptual design, drawing, actual
prototyping and finally inspection and performance evaluation.
2) Fundamental knowledge of design will equip the students with the ability to conceptualize a product that
will meet the functional requirements:
3) As they try to fabricate they will face the actual production problems and they will have to think out of the
box to find innovative solutions.
Examples of some challenging projects with innovative solutions:
1. Fabrication of 50 µm Shaft of 10 mm length
Usually, if a manufacturing engineer is asked to fabricate a micro shaft that is 50 µm in diameter and 10 mm in
length, he will argue that it is impossible. The usual reasons why such a narrow shaft can not be machined are
insufficient stiffness of the product which will deflect due to the cutting force because the engineer will think
only of a turning process from the free end of the blank up to the desired length by longitudinal turning and in
this process these dimensions cannot be achieved. However, engineers tend to forget that both the problems of
deflection and cutting force can be taken care of applying the fundamental engineering knowledge. As shown
in equations (1) and (2) they can control the deflection by calculating the step size for which will ensure that
even a 50 µm shaft will be able to withstand the deflection without yielding. If step turning is carried out as
shown in Fig. 4 – Path B instead of Path A, it can be easily performed. Machined shafts are shown in Fig. 5 [3].
Deflection,
….. (1)
Figure 4. Two possible ways to do turning
Bending stress,
………… (2)
Figure 5. Micro Shafts of diameter 50 microns
2. Ductile mode machining of brittle materials
If a manufacturing engineer is asked to machine glass which a brittle material in ductile mode he will also
argue that it is impossible. However, if he is given some clues explaining the fundamental properties of brittle
materials that every brittle material has a ductile layer on it (Fig. 6) [4], he will be able to unravel the challenge
and be easily able to machine brittle materials in ductile mode. It up milling is considered, chip thickness will
increase from 0 mm to maximum depending on feed rate (Fig. 7) and cracks will start and continue. In the
following cuts, this will be repeated and finally a crack free smooth surface will be achieved. Thus, through
proper selection of cutting conditions, brittle mode machining can be changed to ductile mode (Figs. 8 and 9)
[4].
Figure 6. Plasticity of Brittle Materials
Figure 8. Ductile mode up mmiloing of silicon
Figure 9. Examples of three modes of machining
3. Development of Simumtaneous EDM and ECM process [5].
Micro-EDM milling is a versatile method to fabricate micro-shape due to the negligible cutting force. However,
there are some drawbacks which reduce the capability of micro-EDM milling. Firstly, because the material is
removed by the discharge, the generated is rather rough due to the overlapped craters. Secondly, the material is
removed by melting and vaporization. As a result, there exist the heat affected zones on the machined surface.
The material properties are changed in these zones and they may contain some micro-cracks. For these
reasons, micro-ECM has been combined with micro-EDM to improve the surface finished of machined shapes.
However, it is merely combined as sequential machining processes (do micro-EDM first, and then change to
micro-ECM). This method requires the change of machining fluid or machine set-up. So it is also problematic.
Therefore, combination of micro-EDM and micro-ECM process in the same process is demanded. However,
the different machining fluid issue must be resolved.
Figure 10. Approach to perform Simultaneous Micro EDM & ECM (SEDCM)
As it is known that micro-EDM uses dielectric fluid, which is non-conductive. In contrast, micro-ECM uses
electrolyte which is a conductive fluid. So, an attempt has been made to combine them in the same process.In
this study, low-resistivity deionized water has been used (Fig. 10). In other words, the water is partially
deionized (0.1 – 0.5 Mohm.cm). (Fully deionized water ~ 18 Mohm.cm). Within this range, the fluid is slightly
conductive so it can promote a weak electrochemical reaction. Besides, it still has enough dielectric strength
for the sparks to occur (Fig. 11).
Brief description of SEDCM milling (Fig. 12):
Firstly, power is supplied to the electrode and the workpiece in terms of short voltage pulses. The electrode is
lowered to reduce the electrode-workpiece gap. Secondly, when the gap reaches critical distance, the sparks
occur and material is removed by the discharges. As a result, the gap is increased due to the removed material.
When the gap becomes higher than the critical distance the spark stops. With the continuous supply of voltage
pulses, the electrochemical reaction occurs and the material is dissolved. Especially, thanks to the short voltage
pulses, the dissolution area is localized within a fine gap, marked with dotted line. Hence, the dimensional
accuracy could be maintained. Then, the electrode moves horizontally through feeding and the process repeats.
Finally, combining these two processes and performing simultaneously, a surface roughness of 142 nm has
been improved to 22 nm (Fig. 13).
Conclusions
1. Industrial development is the main driving force for the mechanical engineers. Therefore mechanical engineers
play a pivotal role in economic growth. As such, development is reliant on their actions, productions and
innovations.
Figure 11. Conditions for (SEDCM)
Fig. 12 EDM milling using (SEDCM)
Figure 13. Nanometric Surface Finish by Simultaneous Micro EDM & ECM Processes
2. Mechanical engineers need to get more involved in industrial and economic development of their countries
by helping the government to plan for sustainable development.
3. Mechanical engineering curriculum needs to be updated and upgraded to inculcate innovative minds in
future engineers. They should be inspired to be innovate and creative. Once they get the taste of
innovation, they will get more interested and enthusiastic about engineering and drive the economy.
4. To remain in the path of sustainable development, engineers will have to remain vigilant, innovative and
creative.
REFERENCES
[1] Constantine Ziogas,“ Economics” Oxford University Press(2008), pg. 121.
[2] http://www.bbc.co.uk/schools/ks3bitesize/science/images/globalwarming.gif
[3] Rahman, M, B M A A ABU, T Masaki, T Saleh, Y S Wong and A Senthil kumar, "A Multiprocess
Machine tool for compound micromachining". International Journal of Machine Tools & Manufacture,
(2009). (U K).
[4] ARIF, M, M Rahman and Y S Wong, "Ultraprecision ductile mode machining of glass by micromilling
process". Journal of Manufacturing Processes (SME), 13, no. 1 (2011): 50-59.
& ' Nguyen, M. D., M. Rahman, Y. S. Wong, Enhanced surface integrity and dimensional accuracy by
simultaneous micro-ED/EC milling, Annals of CIRP, 2012.
Invited Talk-23
Prof. Vinod Yadava
Mechanical Engineering Department
Motilal Nehru National Institute of Technology Allahabad
Allahabad, India
HYBRID MODELLING OF HYBRID MACHINING OF HYBRID MATERIALS
Market demand of today generation has posed challenges in the area of materials development of hybrid nature
for superior service performances.Such materials are popularly known with the name of hybrid materials or composite
materials. Composite materials are combination of two or more physically distinct phases of materials (matrix and
reinforcing). The matrix materials provide support to reinforcements while the reinforcing materials enhance the strength
of composite materials. Based on the physical and chemical nature of matrix, the composite materials are classified into
three groups such as Metal Matrix Composites (MMCs), Ceramic Matrix Composites (CMCs) and Polymer Matrix
Composites (PMCs). MMCs are those materials in which matrix are metal or alloy while reinforcing are ceramics. CMCs
are those materials in which both phases i.e. matrix and reinforcing are ceramics. In PMCs, the matrix phase is polymer
while reinforcing phase is ceramics. Further advancement of technology in the field of modern manufacturing need more
superior properties of hybrid materials without loss of functional properties. To meet these challenges, researchers are
adding additional phase of reinforcement into single reinforced composites and such developed composited are known as
hybrid composites.
Recently, hybrid machining processes (HMPs) which are combination of two or more machining processes have
attracted special attention of those who are working in the field of machining of hybrid materials. These HMPs are
developed to exploit the potential advantages and to restrict the potential disadvantages with an individual constituent
processes.The main objectives of the HMPs are: to utilize the advantages and at the same time to reduce or avoid the
disadvantages or limitations of constituent machining processes, to achieve higher material removal, to improve surface
quality, to reduce specific energy requirement, to minimize the production cost and to develop the eco-friendly
machining system that can help to achieve the rapid demands of modern manufacturing industries with efficiently at low
production cost. Usually, the performance of hybrid process is better than the sum of their constituent processes
performance with the same parameter settings. In some of these processes, besides the performance from individual
component processes, an additional contribution may also come from the interaction of the component processes. HMPs
are either abrasion–erosion based or erosion–erosion based. In abrasion–erosion based HMPs abrasion process plays
dominant role whereas erosion process has supportive role. In erosion–erosion based HMPs, machining is performed by
erosion only. Recently, feasible HMPs have been developed by combining EDM, ECM and Grinding.
The abrasion–erosion based hybrid machining processes (AE-HMPs) are developed by combining EDM and
ECM with loose abrasives or bonded abrasives and they are most commonly used in industries [14]. These processes are
Electro-Discharge Abrasive Machining (EDAM), Electro-Chemical Abrasive Machining (ECAM), Electro-Chemical
Abrasive Grinding (ECAG), Electro-Discharge Abrasive Grinding (EDAG) and Electro–Chemical Abrasive Honing
(ECAH). Electro-chemical abrasive grinding (ECAG) with metal bonded rotating abrasive tool is a combined process of
mechanical grinding and ECM. Improvement in performance of this process is due to improvement in surface layer
properties and reduction in tool wear and energy consumption. In this process, about 90% of the material is removed by
electro-chemical means and rest by abrasion. Electro-discharge abrasive grinding (EDAG) is a hybrid machining process
involving EDM and Grinding. In this process, synergetic interactive effect of electro-discharge action and abrasion
action are employed to increase machining performance. The electrical discharges of EDAG cause considerable decrease
in grinding forces and grinding wheel wear along with effective resharpening of grinding wheel. The abrasive action in
this process helps to increase MRR and surface quality.
Erosion–erosion based hybrid machining processes (EE-HMPs) are conceived to overcome the major
limitation of ECM and EDM in which tool and workpiece are required to be electrically conducting and also to increase
the productivity. ECM is characterized by high surface integrity, improved surface finish, high machining rate, and the
absence of tool-electrode wear. But as compared with EDM, it has low accuracy of reproduction of the tool electrode
shape into the workpiece. EDM can provide a high surface finish only with a low productivity. An increase in the EDM
rate results in a significantly higher roughness and deeper damaged surface layer. However, a reduction in surface
roughness leads to increase of the tool electrode wear. A combination of ECM with EDM in one process has shown to
contain the benefits of both processes, provided that the parameters of the combined process are properly
selected.Electro–Chemical Spark Machining (ECSM) is one of the HMPs, which combines the features of ECM and
EDM. ECSM has successfully overcome the limitation of electrical conductivity requirement of the workpiece material
to be machined by EDM or ECM. Also, the MRR by ECSM has been found 5 and 50 times faster than that of ECM and
EDM respectively under the same parameter setting. ECSM was presented for the first time in 1968 by Kurafuji as
“ Electrochemical Discharge Drilling” for micro holes in glass. Several other names of ECSM are used in literature by
different researchers, such as “ Electrochemical Arc Machining (ECAM)” by Kubota, “ Electrochemical Discharge
Machining (ECDM)” by Ghosh et al., and “ Spark Assisted Chemical Engraving (SACE)” by Langen et al. The diversity
of names illustrates the complexity of the process.
Modeling of manufacturing processes are very important issues in manufacturing engineering in general and
machining process in particular. Mathematical modelling is the scientific way to study quantitatively any manufacturing
process behaviour which helps to get the better understanding of the process. Such a mathematical model is an
idealization of the real process behaviour and never be a completely accurate representation. The mathematical models
can be used for simulation and/or optimization and/or control of the process. The prime aim of mathematical modelling
of manufacturing process is to develop a predictive capability for manufacturing performance in order to facilitate
effective planning about manufacturing process to achieve appropriate production rate, product quality and cost. The
most commonly used mathematical modelling techniques are: Experimental, Analytical and Mechanistic.
Experimental (or empirical) modelling is developed using the measured values of input and output process
parameters. These values for developing the model are collected by conducting the experiments on experimental setup.
Experimental models are realistic in nature and hence no assumption is required for developing these models. These are
more suitable for new situations where the physics of the situation is not well known. The error can be possible for
developing these models during conducting the experiments and during measuring the inputs and outputs. These models
are applicable within the certain range restricted with the capability of experimental setup. High experiment cost and
large experimentation time are the major limitations for the development of these models. Regression Analysis
methodology (RAM), Response Surface methodology (RSM) and Neural Network methodology (NNM) are the most
commonly used modelling techniques used for developing model for a manufacturing process based on the experimental
data set.
Analytical models are established the relationship between the inputs and outputs (mostly in differential equation
form) by analysing the physics, chemistry and mathematics of the process. These are more versatile and can be used for
any process without availability of experimental setups and machines. But sometimes mathematical equations required to
describe the process behaviour becomes very complicated and finding solutions of these complicated equations becomes
difficult. Hence, to make equations in a solvable form, sometimes assumptions are made which makes problem
description away from the real solutions. These models may be purely deterministic or probabilistic in nature. Analytical
models are used for well-established and already known process but these are not suitable for new situations where
physical phenomenon is not completely known. The solution of analytical model may be a closed form solution or
numerical form of solution. The analytical models which are solved by numerical techniques such as finite element
method (FEM), finite difference method (FDM), finite volume method (FVM) or boundary element method (BEM) are
also called as Numerical models. The problems associated with experimental modelling and analytical modelling can be
significantly reduced by the use of hybrid modelling. The hybrid modelling is a blended combination of both analytical
and experimental modelling approaches and it tries to capture the capability of both. But it is rigorous approach of
modelling and consumes more time.
Invited Talk-24
Dr. Dipayan Sanyal
CSIR-Central Glass and Ceramic Research Institute
196 Raja S.C. Mullick Road
Kolkata 700032
Email : [email protected]
Near Net Shape Manufcturing Techniques for Fabrication of
Precision Glass and Ceramic Components
Near net shape fabrication of precision glass and ceramic components has been attracting a great deal of
attention for strategic and commercial applications. Unlike metals and alloys, glass and ceramics are not easily
machinable due to brittleness. Creating complex 3D components out of glass and ceramics has always posed a
challenge from manufacturing point of view. The conventional manufacturing process chain of precision glass
optics, both in India and Europe, comprises multi-step grinding and polishing of glass preforms in various
sizes and shapes, typically of cylindrical, polygonal or spherical geometry. The conventional process is too
long and costly to qualify as a mass production technique for millions of camera lenses, CD/DVD pick up
lenses, lens for optical sensors and laser optics, micro lens array, hologram devices and so on for meeting
strategic and commercial interests. CSIR-CGCRI has led an international team of researchers through an India
EU FP7 project and has recently developed a precision forming process chain for rapid and near net shape
manufacturing of glass optics which replaces the multi-step grinding-polishing route with a single step process
with higher yield and improved economy. For rapid net shaping of ceramic components, CSIR-CGCRI has
adopted advanced techniques of laser based additive manufacturing and spark plasma sintering (SPS)
processes where ceramic powders are sintered either layer by layer or as a pre-compacted mass to produce the
net 3D shape of the component. The salient aspects of these manufacturing processes with some emphasis on
process simulation and optimization are highlighted in this paper.
Invited Talk-25
Dr. K.Ramesh Kumar
DRDL, Hyderabad
Manufacture of Thin Walled Tubes by Flow Forming
for Aerospace Applications
Flow forming is an incremental metal forming process in which thin walled cylindrical parts are formed
out of short thick rings called performs over a rotating mandrel by using one or more rollers. Conventionally
thin walled tubes are manufactured by rolling and welding of sheets of required thickness, cold drawing and
extrusion processes. But many of these processes are having limitations in manufacturing of thin walled tubes
with stringent dimensional and form accuracy. The performs for Flow forming can be machined out of
forgings, extrusions, deep drawn and hot formed cups. The performs should be of uniform hardness and grain
size in order to flow form tubes of required dimensional and form accuracy. All the metals which are having
sufficient ductility to be cold formed by any other metal process can be flow formed. The advantages of flow
forming process include avoiding of welding, superior dimensional accuracy, strength increase and good
control of wall thickness variation.
With the advent of new materials development for aerospace applications and due to its inherent
advantages, Flow forming is gaining importance over the other processes in recent times. Currently lot of
research studies are being carried out to understand and simulate the Flow forming process in order to produce
the tubes of required accuracy with optimum process parameters like mandrel speed, feed rate, roller geometry,
roller axial stagger, roller in-feed and percentage reduction.
In addition to all the advantages due to ease of fabrication and superior dimensional and form
tolerances achievable, there is an advantage of a weight reduction of 15-20 % and thereby increasing the
performance of the Aerospace systems. In Defence Research and Development Laboratory, Hyderabad, Rocket
Motor Casings, Airframe Sections of different missiles are manufactured by this process. General issues of
design of performs, mandrel, toolings and process parameters, simulation studies will be discussed and
experiences gained during the development of flow forming process for manufacturing of some of missile
sections out of different materials will be presented.
Abstracts of Machining Papers
Paper #AIMTDR-O0020 (Oral presentation)
Analysis of Surface Roughness in Turning with Coated Carbide Cutting Tools:
Prediction Model and Cutting Conditions Optimization
A. J. Makadia1* and J. I. Nanavati 2
Darshan Institute of Engineering. and Technology, Rajkot-363650
E-Mail: [email protected]
2
Faculty of Engineering and Technology, Baroda-390001
1*
This investigation focuses on the influence of cutting parameters (cutting speed, feed rate and depth of cut) and
tool geometry (tool nose radius) on the surface roughness in turning of AISI 1040 steel using coated carbide
cutting tools. The machining experiments were conducted based on (34) full factorial design. The results
indicated that the feed rate was the dominant factor on the surface roughness; on the other hand both tool nose
radius and cutting velocity have statistical significance on surface roughness. Response contour and surface
plots are generated for the study of interaction effects of cutting conditions and tool geometry on surface
roughness. The analysis of results revealed that combination of low feed rate, high tool nose radius and high
cutting speed is necessary for minimizing the surface roughness. Response surface optimization shows that the
optimal combination of machining parameters are (270.303 m/min, 0.1 mm/rev, 0.3 mm, 0.91 mm) for cutting
velocity, feed rate, depth of cut and tool nose radius respectively. In addition, a good agreement between the
predicted and measured surface roughness on the machining of AISI 1040 steel with 95% confidence interval
within ranges of parameters studied.
Keywords: RSM, Surface roughness,Turning
Turning of Hardened H13 Steel with Interrupted and Continuous Surfaces using
Multilayer Coated Carbide Tool
R. Suresh1* and S. Basavarajappa2
Department of Mechanical Engineering., Alliance College of Engineering and Design, Alliance University,
Bangalore-562106, Karnataka, India
*
2
Department of Mechanical Engineering, U.B.D.T. College of Engineering, Davangere-577004, Karnataka,
India,
1*
Turning of hardened steels has been used increasingly to replace grinding/finishing operations due to the
development of advanced tool materials and rigid machine tools, which can ensure the same accurate
geometrical and dimensional tolerances. However, when turning of interrupted surfaces, the tool requires not
only these properties but also sufficient toughness to resist impacts against work piece interruptions. In the
present study, performance of multilayer hard coatings (TiC/MT-TiCN/Al2O3) on cemented carbide substrate
using chemical vapor deposition (CVD) for turning of hardened AISI H13 steel (50 HRC) was evaluated.
Performance evaluation of the multilayer coated carbide tool was done on the basis of tool flank wear and was
supplemented by cutting force and surface roughness analyses. The results show that the thrust force and
cutting force increases with increased depth of cut and feed rate, while reduces with increase in cutting speed
in both continuous and interrupt cutting. The tool flank wear was influenced mainly by the cutting speed
followed by feed rate. Within the investigated range, abrasion and plastic deformation were deliberated to be
the active wear mechanisms for the multilayer coated carbide tool. The feed rate was the dominant
factoraffecting work piece surface quality. The main conclusions of this work were that in both continuous and
interrupted cutting, the multilayer coated tools exhibited a better performance with respect to both tool life and
workpiece surface roughness.
Keywords: Hard turning, Coated Carbide tool, Cutting forces, Tool Wear, Surface Roughness
Preliminary Experimental Investigation on Multi-Tool Turning Process
R. Kalidasan1, M. Yatin2, S. Senthilvelan3* and D.K. Sarma4
1,2,3
Department of Mechanical Engineering, Indian Institute of Technology Guwahati Guwahati-781 039,
E-mail: [email protected](2E-mail: [email protected]( 3*E-mail: [email protected]
4
Department of Mechanical Engineering, National Institute of Technology Meghalaya Shillong-793 003,
4
1
Productivity affects the economic aspect of all the machining process. One of the method of increasing the
productivity is to use high speed machining, so that the machining time can be reduced. In the present study, a
attempt is made to enhance the productivity by employing two single point cutting tools which are engaged
simultaneously while turning. A fixture is developed to hold the second tool over the Lathe carriage at the rear
side. A single point cutting tool is mounted on the front tool post and rear tool post, which are being separated
by the offset distance. In this work a piezoelectric dynamometer is used to measure the tangential cutting force
and feed force. The objective of this work is to make an experimental investigation on the distribution of
cutting forces and feed forces on the front and rear cutting tools at various offset distances and at different
depth of cut during Multi-tool turning process. It was found that the forces increased proportionately with the
increase in depth of cut and the magnitude of increase of forces for front cutting tool and rear cutting tool is
different.
Keywords: Multi-tool turning process, Cutting force, Feed force, Offset distance.
Experimental Comparative Study of Conventional and Micro-Textured Tools during
Machining of AISI 1040 Alloy Steel
Rokkham Pavan Kumar Reddy1, Kishor Kumar Gajrani2 and M. Ravi Sankar3*
1, 2, 3*
Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Guwahati, 781039
E-Mail1:[email protected], E-Mail2:[email protected], E-Mail3*:[email protected]
In the field of dry machining, recent researchindicates that surface texture has potential to influence
tribological conditions. However, very little attention has been given to controlled surface texturing of cutting
tools. An experimental study of the performance of the micro-texture high speed steel (HSS) grade M2 cutting
tool in machining of AISI 1040 steel samples is carried out. Surface textures were made using Rockwell
hardness tester on rake face of the HSS M2 tool. Structural analyses are done on cutting tool using ANSYS
workbench to evaluate the effect of micro-texture on the stresses and strains generationat cutting edge of the
cutting tool in cutting operations. It is found that the effect of micro-texture on stress generation is very small
which can be neglected. Dry cutting tests were carried out on AISI 1040 steel sample using lathe machine with
micro-textured tools and conventional cutting tool for a varying range of feed and cutting speed. The
machining performance was analyzed in terms of feed force, cutting force and coefficient of friction. The
results demonstrate that the surface texture on the rake face of cutting tools significantly reduces cutting forces
and coefficient of friction when compared with that of the conventional tool.
Keywords: Surface texture, Cutting tools, Dry cutting
Paper #AIMTDR-O0064 (Poster)
Surface Texturing By Using Patterned Grinding Wheel
Do Sup Han1, Kang Qui2, Tae Jo Ko3* and J.K. PARK4
Yeungnam university, South Korea, 712-749, E-Mail :[email protected]
2
Yeungnam university, South Korea, 712-749, E-mail :[email protected]
3*
Yeungnam university, South Korea, 712-749, E-mail :[email protected]
4
Korea Institute of Machinery & Materials, South Korea, 305-343, E-mail : [email protected]
1
Surfaces having local, regular groove cavities arranged in a regular way show many advantageous features,
regarding mainly tribological effects. The main features of regular surface texture (RST) are: reduction of fluid
and boundary friction coefficients, absorption of small hard particles from the lubricant, reduction of residual
stress and shape deviation, better leak-tightness of static and dynamic couplings and better adherence of
coating and adhesive bonds [1]. There are many ways to generate patterned surface such as mechanical as well
as chemical methods. Each process has its pros and cons. In order to generate patterned grooves on the large
area in a short time, grinding is one of the proper processes. In this paper, surface texturing by using patterned
grinding wheel is introduced. Stepien [1] initiated the surface texturing by grinding, followed by the Denkena
et. al [2] However, it is necessary to investigate the generated surface pattern geometry much more with
respect to the grinding conditions. For example, the groove inclination angle as well as the width of the groove
is dependent on the wheel speed, wheel feed rate, and the helix angle of the groove on the wheel surface. To
this end, the experiments were done by the grinding system as shown in Fig. 2. From the experiments, the
inclination angle in addition to the groove width was changed as shown in Fig. 4. Those tendencies will be
used for the design of the surface pattern next.
Keywords :Feed rate, Grinding, Wheel, RPM
An Effective Method to Determine the Optimum Parameters for
Minimum Quantity Lubrication (MQL) Grinding
Dinesh Setti1*, Manoj Kumar Sinha2, Sudarsan Ghosh3 and P Venkateswara Rao4
Department of Mechanical Engineering, Indian Institute of Technology Delhi, 110016,
1*
E-Mail: [email protected]( 2E-Mail: [email protected], 3E-Mail: [email protected]
4
1*,2,3,4
The present trend in the manufacturing industry is to make machining processes more environment friendly by
adopting topractices such as dry machining, minimum usage of cutting fluid, and usage of non-reactivegas
based coolants etc., The concept of Minimum Quantity Lubrication (MQL)has been suggested by several
researchers long time back as a cause for addressing the environmental, healthand economic issues related with
conventional bulk cooling processes. The MQL technique consists of atomizing a very small quantity of
cutting fluid into fine droplets. In other words, the effectiveness of MQL system depends on the quality of
these droplets. This paper presents the combination of microscopy and image processing techniques to
ascertain the quality of droplets,by spraying the MQL fluidonto an acrylic sheet. The raw droplet features
arecaptured with stereo zoom microscopeandanalyzed by measuring the average droplets size and number of
droplets per unit area. Reliable MQL application is achieved when the MQL parameters like the distribution of
the droplets,the applied carrier gas air pressure, fluid flow rate, nozzle tip to machining zone distance, and the
angle at which the nozzle keptis optimal.The optimal MQL conditions as obtained from theseresults have been
usedto improve the grindability of Ti-6Al-4V.
Keywords: MQL, image processing, grinding, droplets
Paper #AIMTDR-P0070 (Poster)
Optimal Selection of Parameters in Multi Tool Drilling by Improved Harmony Search
Algorithm
V.Durga Prasada Rao1*, A.Balakrishna2 and V.Sai Surendra3
Dept. of Mech. Engg., SRKR Engineering College, Bhimavaram-534204,
2
Dept. of Mech. Engg., SRKR Engg. College, Bhimavaram,
3
Dept. of Mech. Engg, K.L.College of Engg, Vijayawada,
1*
In Multi-tool drilling operation, the final size of hole may be obtained by drilling with a single drill or pilotdrilling of one or more holes followed by enlargement to the final size. The machining parameters such as
speed and feed, significantly affects production rate, quality, power required and cost of the component in such
processes. It is found in the literature that, the optimal machining parameters in multi tool drilling for a
particular set of standard HSS drill diameters are obtained for two pass drilling when compared to direct
drilling, three pass drilling, four pass drilling and five pass drilling. The corresponding optimization problems
are solved by different non-traditional optimization algorithms such as Genetic Algorithm (GA), Simulated
Annealing (SA), and Ants Colony Algorithm (ACO). In the present study, the optimization problem on multi
tool drilling is defined by considering drilling cost as the objective with the restrictions on tool life, thrust
force, torque and power. The problem is then solved by using a non-traditional optimization algorithm called
Improved Harmony Search (IHS). The results obtained by the present study are compared with those reported
in the literature, and are found to be good.
Keywords: Multi tool drilling, Harmony search, speed, feed.
Evaluation of Structural Geometry for Mini Milling Machine by Boolean-Algebra
Technique
S.B.Chandgude1 and S.S.Patil2*
1
KKWIEER, Nasik,422003,
2*
KKWIEER, Nasik,422003,
This report shows the details and results of operations concerning the selection of geometric kinematic
structure for a modification in designed milling machine, with regards to the generation and pre-selection of
the numerous variants with reference to present structure. The selection of a suitable layout can best be carried
out by structural analysis using the Boolean-algebra technique (BAT). In this method, the machine tool
structure of any complexity can be represented in the form of a combination of symbols (with 5 variants). By
this technique from various alternatives (5!=120) get the best fit options (4) which fulfill the all constraints and
out of these options select the best fit option.(XYOZC)
Keywords: Boolean-algebra technique, structural design, Geometric Kinematic structure.
Determining Cutting Force Coefficient from Instantaneous Cutting Force in Ball-End
Milling
Mithilesh Kumar Dikshit1*, Asit Baran Puri2, Atanu Maity3 and Amit Jyoti Banarjee4
1*
Department of Mechanical Engineering, NIT Durgapur, Durgapur - 713209,
2
Department of Mechanical Engineering, NIT Durgapur, Durgapur - 713209,
3
Advance Design & Optimization, CSIR-CMERI, Durgapur - 713209,
4
Manufacturing Technology Group, CSIR-CMERI, Durgapur - 713209,
Specific cutting force coefficients play an important role in study of cutting forces in ball end milling. Due to
the complicated geometry of ball end milling cutter the effective diameter of the tool (with active cutting
edges) varies along the axis of the tool during machining which leads to the discrepancies in the prediction of
cutting forces. In this paper, an improved method of identification of specific cutting force coefficient is
proposed for ball end milling cutter. The cutter is discretized into finite number of axial discs along the axis of
the cutter. A semi-mechanistic force model is adopted to relate the cutting forces in each disc and specific
cutting force coefficients are calculated by inverse method and a fourth order polynomial fitting has been
obtained. Several experiments were carried out at different feed and depth of cut to calibrate the proposed
identification method and the same is used for predicting the cutting forces. The shearing force coefficients
have larger value at lower depth of cut and they decrease with increase in depth of cut. Edge force coefficients
do not vary with the depth of cut significantly.
Keywords: Ball end milling, cutting forces, force coefficients, polynomial fitting
An Experimental Investigation on End Milling of Si3N4
1
V.Krishnaraj1 and P.Kuppan2*
PSG College of Technology, Coimbatore 641004, India
E-Mail:[email protected]
2
*VIT University, Vellore 632014, India
Machining of advanced ceramics such as silicon nitride is feasible under controlled cutting conditions. In this
paper experimental work has been carried out on silicon nitride in ductile-regime mode are presented during
end milling. End milling tests using PCD are carried out for depths of cut ranging from 10 m to 50 m. From
the experiments it is found that when the depth of cut is increased the thrust force acting on the cutting tool
increases. This facilitates the ductile transition by providing high pressure field in that cutting zone because of
the high thrust force. The average minimum roughness is found to be nearer to 30 µm depth of cut.
Keywords: End milling, silicon nitride, ductile-regime machining, average minimum roughness
Modeling and Optimization of Milling Parameters on Al-6061 Alloy Using MultiObjective Genetic Algorithm
Rishi Kumar1*, M. K. Pradhan2 and Rajesh kumar3
Maulana Azad National Institute of Technology, Bhopal, 462051
E-Mail1*: [email protected], E-Mail2:[email protected], E-Mail3:[email protected]
Quality and productivity are the two important issues faced by any industry. In order to sustain in a
competitive market, ensuring quality of the product at minimum cost is essential. Machined parts are greatly
influenced by the surface quality during their useful life and productivity also plays an important role in the
existence of any product in the market. In order to achieve that, the process parameters should be suitably
regulated, but both the responses are conflicting in nature as Surface Roughness (Ra) is to be minimized and
Material Removal Rate (MRR) is to be maximized. Hence, modeling and optimization of any process are
getting attention by researchers. This paper presents an approach for determination of the best cutting
parameters leading to minimum Ra and maximum MRR simultaneously by integrating Response Surface
Methodology (RSM) with Multi-Objective Genetic Algorithm (MOGA) in face milling of Al-6061 alloy.
Thirty experiments have been conducted based on RSM with four parameters, namely Speed (v), Feed (f),
Depth of Cut (d) and Coolant Speed (c.s) and three levels each. ANOVA is performed to find the most
influential parameters on both MRR and Ra. It is revealed that f and d are the most influential parameters on
MRR and c.s is the most influential parameter for Ra, respectively. Later the multiobjective optimization tool
GA is used to optimize the responses. A pareto-optimal set of 21 solutions is obtained and validated through
confirmation test.
Keywords: Face milling, Response surface methodology, Multi-objective GA.
Modeling and Optimization of End Milling Parameters on Aluminum 6061 Alloy Using
GRA based Taguchi Method Coupled with PCA
Rajesh Kumar1*, M. K. Pradhan2 and Rishi kumar3
Maulana Azad National Institute of Technology, Bhopal, 462051
Email: [email protected], [email protected],[email protected]
Quality and productivity are two important aspects for manufacturing industries. Modeling and optimization is
the best technique applied to find the best manufacturing conditions. This technique has been applied to
investigate the optimized design of the cutting process in end milling for Al 6061 alloy in order to provide
better surface finish as well as high Material Removal Rate (MRR). The cutting parameters considerd are
coolant employment, spindle speed, feed, and depth of cut. The Al 6061 alloy has a wide variety of
applications in automobile industries as well as aerospace industries due to its light weight to strength ratio,
high corrosion resistance, heat treatable and easily weldable property. The experiments were conducted on L18
(21×33)orthogonal array, Analysis of Variance (ANOVA) was used to obtain individual optimization latter
Grey Relational Analysis (GRA) based Taguchi method has been used for effective optimization. A Gray
Relational grade found out by the GRA has been used to obtain the best end milling process parameters with
multiple performance characteristics. In order to evaluate the weighting values corresponding to various
performance characteristics, principle component analysis (PCA) has been used so that their relative
importance can be objectively described. Graphs and response table were used to find the optimal levels of
parameters in end milling process. Finally, a comparison between the experimental results and developed
model was obtained using conformation tests. The machining performance in the end milling process can be
improved effectively by applying this technique.
Keywords: End Milling, Taguchi Method, Grey Relational Analysis, Principle Component Analysis.
HSS Tool Wear Mechanism in Machining of HTBP Based Composite Propellant Grain
Kishore Kumar Katikani1,Vanapalli Srinivasa Rohit 2,Anne Venu Gopal 3* and V.V. Rao 4
1
NSTL,DRDO,Visakhapatnam-530027,Email: [email protected]
2
NIT Warangal -506004, Email: [email protected]
3
*NIT Warangal -506004, Email: [email protected]
SPRITE,ASL,DRDO,Hyderabad -500058 Email:[email protected]
Thrust characteristics of Solid propellant Rocket Motor (SRM) depend on the surface area of the propellant
grain exposed to initial ignition. For controlled combustion of propellant, contours and slots of initial ignition
surface on propellant grain are generated by turn milling operation. Metallic Aluminum powder is the fuel and
Ammonium Perchlorate (NH4ClO4) is the oxidizer in majority of HTPB (Hydroxyl Terminated Polybutadiene)
based composite propellants. Since the propellant being highly inflammable due to these sensitive ingredients,
basic understanding of machining process is very crucial for safety. The present paper focuses on the
mechanism of tool wear of custom made HSS inserts used in machining of propellant grain.
Eight cutting elements used in machining of propellant grain were examined to study the tool wear pattern and
predominant wear mechanism. Flank and rake surface were analyzed to determine the tool wear phenomena.
Microstructure of the machined surface of grain was determined to understand dispersion pattern of the
ingredients in composite propellant. K2 Chemical wear was found to be predominant. Understanding the wear
mechanism helps in development of improved insert or coatings on present insert in machining the solid
propellant rocket motor.
Keywords: HSS insert, Chemical wear, Propellant machining, and Solid rocket motors
Effect of Direct and Indirect Cryogen Application Methods on the Turning Forces, Tool
Wear and Surface Finish of a Nickel Based Alloy (Nimonic 90)
Chetan1*, Bikash Chandra Behera2, Sudarsan Ghosh3 and P Venkateswara Rao4
1*
Department of Mechanical Engineering, IIT Delhi, 110016, Email:[email protected]
2
Department of Mechanical Engineering, IIT Delhi, 110016, E-mail:[email protected]
3
4
Due to the stricter environment legislation and also due to an increase in the occupational diseases amongst the
workers, it is necessary for the manufacturing sector to shift towards sustainable production techniques. Many
researchers have reported that the application of Cryogen in metal cutting could improve the machinability of
some materials without any ill effects on environment and health of workers. In machining, Cryogen can be
used in two ways: (a) direct method and (b) indirect method. In direct cryogen application method, cryogenic
gas from a suitably designed nozzle is directly applied to the tool-chip interface. While in indirect cryogen
application cryogenic treatment is done on the cutting tool which may be subjected to a temperature below 0 °C
for a prolonged duration of time. This paper presents the comparison between the direct and indirect cryogen
application methods during machining of Nimonic 90, a widely used nickel based super alloy. The
measurement of Tool wear, surface roughness and cutting forces has been carried out for both these methods to
determine the more effective method which can be used successfully during machining of the alloy.
Keywords: Cryogenic cooling, Cryogenic treatment, Machinability, Nimonic, Sustainability.
Application of Taguchi Method for Optimizing Material Removal Rate in Turning of En47 Spring Steel
Yogendra kumar1* and Hari singh2
Mechanical Engineering Department, National Institute of Technology Kurukshetra, India, 136119
E-mail1:[email protected]
2
Mechanical Engineering Department, National Institute of Technology, Kurukshetra, India, 136119
E-mail2:[email protected]
1*
En-47, chromium-vanadium steel, has wide applications in automobile industry particularly in making high
duty volute and leaf spring, heavy engine valve spring, helical and torsional bar springs. Experiments have
been conducted using L-18 orthogonal array standardised by Taguchi. Each experiment is replicated three
times on a centre lathe by using new cutting carbide insert for each trial to ensure accurate results of the
material removal rate. The statistical methods of signal to noise ratio (S/N) and analysis of variance(ANOVA)
are applied to investigate the effects of four turning process parameters (nose radius, cutting speed, feed rate,
depth of cut) on material removal rate. The Figure 2 reveals the optimal setting of process parameters for
optimized value of MRR. The optimized value of MRR is 1.344 g/sec. Confirmation test with the optimal
levels of cutting parameters shows that the optimized value of MRR falls within 95% confidence level.
Analysis of variance (Table 6) shows that all the four selected process parameters are significant at 95%
confidence level in affecting the response since their p-values are less than 0.05.
Keywords:Turning process, Taguchi technique, En47 steel, MRR.
Process Parameter Optimization in Multi-Pass Turning Operation Using Hybrid Firefly
Swarm Algorithm
1*
R.Gayatri, 2M.Malarvizhi and 3N.Baskar
1*
Department of Computer Applications, M.A.M College of Engineering and Technology, Tiruchirapalli 621105, Tamilnadu, India. E-mail: [email protected]
2*
Department of Computer Applications, J.J. College of Engineering and Technology, Tiruchirapalli – 620
009, Tamilnadu, India. E-mail: [email protected]
3
Department of Mechanical Engineering,M.A.M College of Engineering,Tiruchirapalli - 621105, Tamilnadu,
India. E-mail: [email protected]
Evolutionary algorithms are the choice of many researchers for optimizing machining parameters. Even though
evolutionary algorithms are commonly used for solving constrained optimization problems, however in
practice sometimes they deliver only insignificant performance. The difficulty with evolutionary algorithms is
that they start with random initial population and all its populations become grossly identical after a certain
amount of time. Inappropriate selection of various parameters, representation, etc. of evolutionary algorithm is
one of the root causes for the failure for the better performance. All these clearly illustrate the need for hybrid
evolutionary approach. Hybridization is way to improve the existing approach. The objectives of this paper are
i) to analyze the parametric settings of FA that leads to optimized result by apply it in multi-pass turning ii) As
PSO quick in convergence to a best value, hybridize Firefly Algorithm (FA) with Particle Swarm
Optimization(PSO) called Hybrid Firefly Swarm (HFS) algorithm to exploit best parameter setting in multipass turning iii) To explore the convergence characteristics and robustness of the Firefly Algorithm (FA)
through comparisons with results of evolutionary algorithm and with the results reported in literature.
Keywords: Optimization, Hybrid, Evolutionary algorithm
Effects on Forces and Surface Roughness during Machining Inconel 718 Alloy Using
Minimum Quantity Lubrication
Bikash Chandra Behera1*, Chetan2, Sudarsan Ghosh3 and P Venkateswara Rao4
1,2,3,4
Department of Mechanical Engineering, IIT Delhi, 110016
1*
Email:[email protected],2Email:[email protected],3Email:[email protected]
4
Turning operations are one of the most versatile secondary manufacturing processes. In industry,
manufacturing processes are contrived and improved in order to obtain maximum quality and minimum cost.
Requirements of higher machining quality and manufacturing efficiency have led to a great deal of researches
aimed at controlling and planning the metal cutting processes. In manufacturing industries new techniques
have been developed to improve manufacturing performances through better processes, and use of advanced
cutting tools. However, the environmental aspects are increasingly becoming a significant issue. Thus, in
parallel with manufacturing process’ optimization, efforts must be made to reduce the impact of industrial
activity on environment and health. The increasing requirements for environment-friendly cutting processes
enabled use of new techniques like the minimal quantity or even the complete omission of cutting fluids. The
most promising solution to these requirements is MQL machining, which has been performed in the metal
removal process such as milling, drilling and turning. In the present study we compared the effect of forces and
surface roughness data during turning of Inconel 718 under dry, conventional fluid and conventional fluids
under Minimum Quantity Lubrication process.
Keywords: MQL Turning, cutting force, surface finish, Inconel 718
Performance Evaluation of CVD Multilayer Coating on Tool Wear Characteristics
during Dry Machining of Nimonic C-263
A.Thakur1*, S.Gangopadhyay2, A. Mohanty3 and K.P.Maity4
Department of Mechanical Engineering, NIT Rourkela, PIN-769 008, Odisha, India
1*
Email: [email protected], 2Email: [email protected]( 3Email: [email protected]
4
Nimonic C-263 is one of most popularly used nickel-based superalloys particularly used in the field of hot
section part of gas turbines, aerospace, power generators and heat exchangers. It is categorized under difficultto-cut material because of its unique propertysuch as high hardness, fatigue strength, low thermal conductivity,
high chemical affinity and tensile strength along with resistant to corrosion & oxidation. Machinabilitycan be
improved with proper selection of cutting tool and cutting parameters. The present paper deals with
comparative analysis of tool wear and chip characteristics when machining Nimonic C-263 with uncoated and
multilayer coated carbide inserts. Dry turning operation was carried out at two different cutting speeds (51
m/min and 84 m/min) with a constant feed (f) of 0.2 mm/rev and depth of cut (t) of 1 mm. Chip reduction
coefficient ( ) and tool wear were observed during dry machining of Nimonic C-263. It was found that chip
reduction coefficient decreased with increase in machining duration and cutting speed. Whereas flank wear
increased with machining duration for both uncoated and coated carbide inserts. However, uncoated tool failed
only after 90second (s) of machining at a cutting speed of 84 m/min, whereas machining was still possible with
CVD multilayer coated tool after 120 s of machining duration.
Keywords:Nimonic C-263, CVD coated carbide, Chip reduction coefficient, Tool wear.
An Experimental Study on Green Machining
Palash Saikia1 and Manjuri Hazarika2*
Mechanical Engineering Department, Assam Engineering College, Guwahati–781013
2*
E-mail:[email protected],E-mail:2*[email protected]
1
The growing demand for energy in the last two decades involving all spheres of human civilization is an
important issue in need of immediate attention. The need arises to explore means of reducing energy
consumption during machining. Green machining has become an essential and fast developing research area in
manufacturing. In this work, an experimental study is conducted to find the effect of material removal rate
(MRR) on specific energy consumption in milling operation. MRR is varied by varying feed rate and depth of
cut. Variations in specific energy and cutting power requirement with the change in feed rate and depth of cut
(thereby change in MRR) are observed. It is found that with increase in feed rate/depth of cut, MRR is
increased and specific energy is decreased. Although cutting power requirement increases with MRR, decrease
in specific energy due to increasing MRR dominates the increase in cutting power requirement. Use of optimal
feed rate/depth of cut and thus optimal MRR can ensure lower specific energy consumption leading to green
machining.
Keywords: Green machining, Specific energy, cutting power, MRR
Effect of Process Parameters on Convective Heat Transfer Coefficient of Fluid and Heat
Partitioning in High Efficiency Deep Grinding with Water Based Coolant
M. Vashista1* and S. Paul2
Department of Mechanical Engineering, Indian Institute of Technology, (BHU),Varanasi – 221005
2
Department of Mechanical Engineering, Indian Institute of Technology Kharagpur, Kharagpur– 721032
1*
An experimental study was undertaken to investigate the role of process parameters on the convective heat
transfer coefficient of fluid and heat partitioning ratios in high efficiency deep grinding. The convective heat
transfer coefficient has been shown to vary with grinding speed and contact length along the grinding zone.
The ratio of heat partition to different sinks i.e. workpiece, grinding chips, coolant and grinding wheel have
been calculated by using experimental data. Relationship between process parameters and different partitioning
coefficient has been derived. The grinding fluid takes most of the grinding heat away from the grinding zone.
Heat partitioning ratio to the grinding chip increases with material removal rate and takes around 20% of
grinding heat. Very less amount of heat is carried away by workpiece and cubic boron nitride (cBN) grinding
wheel under high efficiency deep grinding conditions while using water based coolant.
Keywords: High efficiency deep grinding; Heat partitioning; Convective heat transfer coefficient
Surface Integrity and Optimization in Turning Ti6Al4V
Satyanarayana.K1*, Ravi.N2 ,Shivaji Babu.K3, Venu Gopal.A4
1*
Mech. Engg. Dept, GRIET, Hyderabad, 500090. [email protected].
2
Sc.- E, ARCI, Hyderabad, 500005, [email protected].
3
Mech. Engg. Dept., PVP Siddhartha Institute of Technology, Vijayawada, 520007, [email protected].
4
Mech. Engg. Dept., N.I.T. Warangal, 506004,[email protected].
The objective of this work is to investigate the effect of process parameters such as cutting speed, feed and
depth of cut and one of the tool geometry parameters such as the back rake angle on surface integrity,
especially the residual stresses. In the present work, turning experiments have been conducted on Ti-6Al-4V
material using tungsten carbide with TiAlN coating as the tool material. Experiments have been conducted
using L9 orthogonal array based on design of experiments. The residual stress induced in the workpiece during
turning has been measured using X-Ray Diffraction (X’ pert Pro MRD) system. Taguchi method is employed
as a statistical design of experiments (DOE) to optimize the process parameters in order to obtain minimum
residual stresses. From these investigations, it is recommended to use cutting speed 75 m/min, feed 0.3
mm/rev, depth of cut 0.75 mm and a back rake angle -3 degrees to achieve minimal residual stresses.
Keywords: Machining, Ti6Al4V, Residual Stress, Taguchi
3D Finite Element Modeling of Thin-Wall Machining Of Aluminum 7075-T6 Alloy
1,2
Gururaj Bolar1 and S. N. Joshi2*
Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Guwahati, 781 039,
1
2
*E-Mail: [email protected]
This paper presents the modeling and simulation of deformation of thin-wall section using finite element
method (FEM). A 3D non-linear numerical model was developed by employing Johnson-Cook material
constitutive model for aluminum 7075-T6 alloy. Johnson-cook damage law was adopted to account for damage
initiation and chip formation during cutting tool penetration into the work material. The deformation of thinwalled part under the action of cutting forces during milling operation was studied for a set of process
conditions and the preliminary results are discussed.
Keywords: Thin-wall machining, numerical simulation, deformation, aluminum 7075-T6
Selection of Machining Parameters in Face Milling Operations for Copper Work Piece
Material Using Response Surface Methodology and Genetic Algorithm
S.Kannan1*, N.Baskar2 and B. Sureshkumar3
Department of Mechanical Engineering, A. V. C. College of Engineering, Mannampandal, Mayiladuthurai,
Tamilnadu, India. Pin: 609 305.
E- mail:[email protected]
2,3
Department of Mechanical Engineeering, M. A. M. College of Engineering, Siruganur,
Tiruchirappalli,Tamilnadu, India. Pin: 621 105.
2
E- mail: [email protected](3E- mail:[email protected]
1*
Face milling operation is one of the essential milling processes and it is used for planning the topsurface of
the component to achieve high accuracy with low roughness. The work enlights the parameters influence on
Material Removal Rate (MRR) and Surface Roughness (SR) in copper as a work piece material. Conseuently
the selection of milling parameters such as spindle speed, feed rate and depth of cut are importnat for
improving the productivity and part quality. This work formulates the relationship between input and response
variables for improving the face milling operation. The Response Surface Methodology (RSM) is used for
making the relationship between independent and dependent variables. The performance of RSM models
show the developed empirical relationship and it has the best agreement with experimental results. The
Genetic Algorithm (GA) is utilized for select the optimal machining parameters.
Keywords: Material Removal Rate, Surface Roughness, Response Surface Methodology, Genetic Algorithm
An Investigation into Selection of Optimum Dressing Parameters Based on Grinding Wheel Grit
Size
Manoj Kumar Sinha1*, Dinesh Setti1, Sudarsan Ghosh2 and P Venkateswara Rao3
1*,2,3,4
Department of Mechanical Engineering, IIT Delhi, 110016
1*
E-Mail: [email protected]*, 2E-Mail: [email protected],3E-Mail: [email protected],
4
With awareness in people and advancement in manufacturing technologies, there is a huge demandfor
precision products. Grinding is a technique often usedto manufacturethe products with precision and
quality.The performance of grinding operation significantly depends on the nature of grinding wheel and
morphology of theabrasive grits used. The nature of grinding mechanism such as cutting, ploughing, and
rubbing depends upon these parameters. Particularly, the grit size and the dressing parameters such asdressing
lead, dressing depth, dressing tool profiledecides the actual grinding processmechanisms along with the
kinematic conditions during the grinding.Moreover, the structure of the grinding wheel can be controlled by
dressing operation, which plays a dominant role inmaterial removal rate and surface finish. In this paper
investigations have been done to obtain the optimum dressing conditions by varyingdressing leadand dressing
depth for grinding forces and surface finishduringsurface grinding.The grinding results indicate that suitable
selection of the dressing parameters for different requirements of grinding operation can be helpful in grinding
processeconomization in industries.
Keywords:Grinding, dressing, dressing lead, dressing depth
An Effective Grinding Fluid Delivery Technique to Improve Grindability of Inconel-600
1
Bijoy Mandal1a, Anirban Sarkar1b, Debashis Biswas1c, Santanu Das1d* and Simul Banerjee2e
Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani- 741235, Email:
a
[email protected], [email protected],
c
[email protected], d*[email protected]
2
Department of Mechanical Engineering, Jadavpur University, Kolkata, India,
High heat generation is a common phenomenon of grinding and conventional fluid delivery system through
nozzle is not so effective due to stiff air layer formed in the periphery of high-speed rotating grinding wheel. It
obstructs grinding fluid to enter the grinding zone. Hence, surface burn of workpiece, high wheel wear, wheel
loading, etc. are commonly found in grinding. These difficulties become acute when grinding a superalloy
which exhibits high mechanical strength, creep resistance and good surface stability at elevated temperature.
These difficult-to-machine alloys are extensively used in making turbine blade, heat exchanger parts, aerospace
application, etc. In this present experimental investigation, a nickel based superalloy, Inconel 600, is ground by
alumina wheel at different infeeds under dry, wet and wet with pneumatic barrier conditions. A pneumatic
barrier is used to break stiff air layer formed around a grinding wheel periphery to allow grinding fluid reach
deep inside the grinding zone. Effects of these environmental conditions have been studied in respect of
grinding force, force ratio, chip formation, wheel condition, surface roughness and G-ratio. Results show
grinding performance is better with the application of wet condition with a pneumatic barrier set-up as it
facilitates coolant reach the grinding zone effectively.
Keywords: Surface Grinding, Flood Cooling, Pneumatic Barrier, Inconel-600
Development of a Portable Intelligence Control System to Reduce Components
Dimensional Variations in Milling
Ganesh Kumar Nithyanandam1* and Radhakrishnan Pezhinkattil2
1
PSG College of Technology, Coimbatore, E-Mail:[email protected]
2
PSG Institute of Advanced Studies, Coimbatore, E-Mail:[email protected]
Dimensional variations on long components while machining is a serious manufacturing problem, particularly
in the case of large batch sizes. When components are machined in milling, dimensional discrepancies are
more when the component thickness are smaller or thinner. Several researchers are working on this field to
minimize this dimensional discrepancies. This paper reveals a methodology to minimize or eliminate the
dimensional variations of the components in CNC milling in real-time using a portable intelligence control
system. This control system consists of an indigenously developed portable plug and play modular fixture
mechanism with servomotor, which has the intelligence to monitor and control (autonomously) the variations
to the targeted value automatically. Aircraft rib component is taken as a case study to demonstrate this study.
Keywords: Process variation, Portable modular fixture, Intelligence control system, Adaptive control system,
Artificial neural network
Optimization of Radial Force in Turning Process Using Taguchi’s Approach
Sumit Verma1* and Hari Singh2
Mechanical Engineering Department, National Institute of Technology, Kurukshetra 136119, India,
[email protected]
2
Mechanical Engineering Department, National Institute of Technology, Kurukshetra, 136119, India,
[email protected]
1*
Efficient turning of high performance EN series material can be achieved through proper selection of turning
process parameters to minimize radial force. Cutting parameters are optimized to minimize radial force in
turning of EN-8 steel using carbide inserts as cutting tool. The experiments are conducted using L18
orthogonal array as an experimental design. The cutting parameters are optimized using signal to noise ratio
and the analysis of variance. The effects of nose radius, spindle speed, feed rate and depth of cut are analyzed.
The confirmation tests are carried out at optimum cutting conditions. Optimal values of process parameters for
desired performance characteristic are obtained by Taguchi’ s approach. The main effect plot (figure 1) shows
the low feed rate and low depth of cut result in minimum value of the radial force i.e., 36.158 N. Table 4
reveals that all the factors i.e., nose radius, spindle speed, feed rate and depth of cut are the significant factors
in affecting the radial force at 95% confidence level.
Keywords: Turning operation, EN-8 steel, radial force, Taguchi’ s approach
Experimental Investigation on Surface Roughness Characteristics in Hard Turning of
EN31 Steel Using Coated Carbide Insert: Taguchi and Mathematical Modeling Approach
1,3,4,5
Panda, A.1, Dutta, S.K.2, Sahoo, A.K.3*, Rout, A.K.4 and Routra B.C.5
School of Mechanical Engineering, KIIT University, Bhubaneswar-751024, Odisha, India
*[email protected], E-Mail1:[email protected], E-Mail4:[email protected], EMail5:[email protected]
2
KIIT Polytechnic, Bhubaneswar-24, Odisha, India, E-Mail2:[email protected]
Now-a-days turning of hardened steel over 45 HRC is an emerging technology replacing grinding operation for
finishing the components. Multilayer coated carbide insert being an inexpensive cutting tool material has less
researched in machining hardened components. Thus, the objective of the present work has been set to have a
study on hard turning of EN 31 steel (55HRC) using TiN/TiCN/Al2O3 multilayer coated carbide inserts
through Taguchi L16 orthogonal array design and investigates surface roughness under dry environment.The
mathematical model has been developed for better prediction of responses using response surface methodology
and correlated for its significance. The mathematical model presented high correlation coefficients (higher R2
value) and fitted well. Feed is found to be most dominant parameter for affecting the surface roughness. A
Taguchi technique has been utilized for parametric optimization of surface roughness. From the study, the
potential and effectiveness of multilayer coated carbide insert has been noticed while turning hardened steels
under dry environment.
Keywords: Hard turning, Surface roughness, Coated carbide, RSM, Taguchi
Integrated Strategies for High Performance Peripheral Milling
Law, M.1,*, Wabner, M.2 and Ihlenfeldt, S.3
Fraunhofer Institute for Machine Tools and Forming Technology IWU,
Reichenhainer Str. 88, 09126 Chemnitz, Germany
E-Mail1,*:[email protected]; E-Mail2:[email protected]; EMail3:[email protected]
High performance peripheral milling is one of the most common rough machining operations in modern
production environments. Productivity of these operations, characterized by material removal rates (MRR) and
machining times,is a function of several parameters:spindle speed, feed, axial and radial depths of cuts, tool
path type, milling mode,and feed direction. Each of these variables affects the MRRs differently; the limiting
case often resulting from the dynamic interactions between the cutting tool and the work piece - characterized
by chatter vibrations.This paper proposes an integratedapproachincorporating all of the significant factors
affecting performance to formulate admixed mode milling strategy for the case of profile-parallel peripheral
milling of a rectangular part. Numerical investigations demonstrate an improvement in machining time of up to
28% over conventional approaches. Proposed methods can be used for selection of optimal cutting conditions,
tool path type, and for dynamically modifying the tool path to maximize MRRs and minimize the machining
times.
Keywords: Machining strategy, Chatter vibrations, Material removal rate, Peripheral milling
Utility Fuzzy Multiobjective Optimization of Process Parameters for CNC Turning of
GFRP/Epoxy Composites
Hari Vasudevan1*,Naresh Deshpande2, Ramesh Rajguru3 and Sandip Mane4
1*,2,4
Department of Production Engineering, D.J. Sanghvi College of Engineering,
Mumbai, India, 400056.
1*
E-mail:[email protected];2E-mail: [email protected];
3
Department of MechanicalEngineering, D.J. Sanghvi College of Engineering,
Mumbai, India, 400056.
3
E-mail: [email protected];4E-mail:[email protected]
Although Glass Fibre Reinforced Plastic (GFRP) composites are usually moulded near-net shape for obtaining
close fits and tolerances, certain amount of machining has to be carried out on them.A number of axisymmetric
GFRP composite parts are finish machined by turning. These include axles, spindles, columns, rolls, bearings,
drag links and steering columns. Quality and productivity are two important, but contradictory parameters
while performing machining operations. Hence, it becomes essential to evaluate the optimal cutting parameters
setting in order to satisfy contradictory requirements of quality and productivity.In this study,a hybrid
multiobjective optimization algorithm involving utility and fuzzy coupled with Taguchi methodology is used.
Four process parameters, each at three levels are selected for the study viz. cutting tool nose radius, cutting
speed, feed rate and depth of cut. Surface roughness parameter Ra, cutting force Fz and material removal rate
MRR are the chosen output performance measures. The experimental plan is laid according to Taguchi’ s
orthogonal array L27. Woven fabric based GFRP/ Epoxy tubes produced using hand layup process are finish
turned using Poly Crystalline Diamond (PCD) cutting tool. Utility values of the three performance measures
are converted into a single Multi Performance Characteristics Index (MPCI) using Mamdani type fuzzy
inference system. This MPCI is then optimized using Taguchi analysis. The parameter combination of
A2B3C1D2, i.e. tool nose radius of 0.8 mm, cutting speed of 200 m/min, feed rate of 0.05 mm/rev and depth
of cut of 1mm, is evaluated as the optimum combination. The confirmatory experiment at these settings gives
maximum value of MPCI validating the results.
Keywords: GFRP/Epoxy, Utility values, Fuzzy inference system, Multiobjective optimization.
Experimental Investigation and Optimization of Milling Parameters in the Machining of
NEMA G -11 GFRP Composite Material using PCD Tool
Hari Vasudevan1, Ramesh Rajguru2*, Naresh Deshpande3 and Sandip Mane4
Principal, D.J. Sanghvi College of Engineering, Mumbai, India, [email protected]
2*
Faculty, Department of Mechanical Engineering, D.J. Sanghvi College of Engineering, Mumbai,
India,[email protected]
3,4
Faculty, Department of Production Engineering, D.J. Sanghvi College of Engineering, Mumbai, India,
[email protected]
1
GFRP/Epoxy composite NEMA G-11 possesses excellent physical, mechanical and electrical properties at
both room temperature & elevated temperatures and finds wide applications, such as insulation in aerospace
and defense systems. The material withstands temperatures in excess of 300°C and is considered a premier
material for use as Class F insulation in electrical power generation and transmission equipments.Milling is
one of the most practical machining processes for removing excess material to produce high quality surface.
However, milling of composite materials is a rather complex task owing to its heterogeneity and poor surface
finish, which includes fibre pullout, matrix delamination, sub-surface damage and matrix polymer interface
failure. In this study, an attempt has been made to optimize milling parameters with multiple performance
characteristics, based on the Grey Relational Analysis coupled with Taguchi method. The milling experiments
were carried out on a vertical HAAS TM-2 CNC Milling machine. The experiments were conducted according
to L18 (OA). The four cutting parameters selected for this investigation are milling strategy, spindle speed,
feed rate and depth of cut. Response table of grey relational grade for four process parameters is used for the
analysis to produce the best output; the optimal combination of the parameters.From the response table of the
average GRG, it is found that the largest value of the GRG is for the up milling, spindle speed is of 1500 rpm,
feed rate of 200 mm/min and depth of cut 0.2 mm. Milling strategies and feed rate have the most dominant
roles in influencing the surface roughness.
Keywords:Milling, Surface roughness, Machining force, Grey relational analysis; Taguchi methodology
An Expert System for Selection of Carbide Cutting Tools for Turning Operations
1,2,3
P. D. Chougule1, S. Kumar2* and H. K. Raval3
Department of Mechanical Engineering, S. V. National Institute of Technology, Surat - 395007, India
E-mail:[email protected], 2*[email protected], [email protected]
Majority of the components machined in industries have cylindrical shapeswith large variety in shape, size and
accuracy. An engineer has to select the tools based on his experience or by referring tooling catalogues which
is time consuming. In the present research work, an expert system is developed for the optimal selection of
carbide cutting tools for turning operation. Technical knowledge acquired from various sources of knowledge
acquisition is refined and framed in form of production rules of ‘IF-Then’ variety. ISO specifications along
with trade names of various leading cutting tool manufacturers are included in the knowledge base of proposed
system. This system determines several parameters such as tool holder (clamping system, approach angle, and
size), insert (shape, size, and nose radius) and cutting condition (speed, feed, and depth of cut). The most
important feature of the system is the cross reference list of inserts. Use of this system will avoid cumbersome
work of referring tooling catalogues of varioustool manufactures.The system has been tested successfully in a
manufacturing industry.
Keywords: Expert system, Turning, Cutting tool selection, Carbide tools
Comprehensive Study of Chip Morphology in Turning of Ti-6Al-4V
Vikas Upadhyay1*, P.K. Jain2 and N.K. Mehta3
Mechanical and Industrial Engineering Department, Indian Institute of Technology Roorkee, Roorkee,
247667, E-mail: [email protected]
2
3
1*
In machining of Ti-6Al-4V alloy, the formation of saw tooth chips takes place at relatively low cutting speeds
in comparison to other materials such as hardened steels. Study of chip morphology is important to understand
the cutting force variation, surface integrity and chip breakability of the alloy. In this work, an attempt has been
made to study the effect of cutting speed, feed rate and depth of cut on saw tooth geometry in terms of peak
height, valley height, tooth height, segmentation degree, tooth pitch, localized shear angle, bulge angle and
chip segmentation frequency, to get better insight about the machinability characteristics of Ti-6Al-4V alloy.
Keywords: Chip morphology; Ti-6Al-4V alloy; turning.
NN-GA Based Modeling and Optimization of Cylindrical Grinding Process
R. Rekha1 and N. Baskar2
1
Department of Mechanical Engineering, Saranathan College of Engineering, Tiruchirapalli, Tamilnadu, India,
Email ID: [email protected]
2
Department of Mechanical Engineering, MAM College of Engineering, Tiruchirapalli, Tamilnadu, India,
Email ID: [email protected]
The present work describes an application of hybrid approach using neural network (NN) and genetic
algorithm (GA) for modeling and optimizing the process parameters in cylindrical grinding of AISI 316
stainless steel. In this study, each experiment was conducted under different machining conditions of cutting
speed, feedrate and depth of cut, and machining performance such as surface roughness and metal removal rate
were evaluated. A Taguchi L9 orthogonal array was employed to plan the experimentation, and based on the
experimental data a regression model was developed to depict the relationship between the machining
parameters and responses. Then, GA was applied to predict the optimal process parameters and to train the NN
model. Experiments were conducted for validation and the results were found to be in good agreement with the
predicted value.
Keywords: Cylindrical grinding, Taguchi L27 orthogonal array, Neural network, Genetic algorithm
A Fuzzy Logic Model to Evaluate Thrust Force in the Drilling of Medium Density Fibre
Board
S.Prakash1*, J. Lilly Mercy2, Dhrubajyoti Baruah3 and Putti Venkata Siva Teja4
1
sathyabama University, Chennai, 600119, [email protected]
2
3
4
Medium Density Fibre (MDF) Board is appropriate for many applications in furniture industry due to its better
machinability, dimensional stability and surface characteristics. Drilling is the unavoidable machining
operation during the assembly of MDF, which plays a major role in the acceptance of the finished product.
Thrust force exerted during the drilling operation plays a major role in deciding the damaged area and the
extent of defects in the work piece. This work is focussed to study the effect of various drilling parameters like
feed rate, spindle speed, drill diameter and board thickness on the thrust force exerted during drilling.
Experiments were planned using L27 orthogonal array and a fuzzy logic rule based model is used to evaluate
the effect of these factors on thrust force. The micro structure of drilled holes is studied through Scanning
Electron Microscope (SEM) and the results are validated.
Keywords: Medium density fibre board (MDF), Scanning Electron microscope (SEM), Thrust Force, FUZZY
Logic.
Multi Characteristics Optimization Using Taguchi Quality Loss Function with Varying
Weightage of Responses in Drilling of GFRP Composite
Sunil Hansda1* and Simul Banerjee2
1*
Mechanical Engineering Department, Dream Institute of Technology, Kolkata-700104,
2
Mechanical Engineering Department, Jadavpur University, Kolkata-700032,
The mechanism involved while cutting composite materials have been regarded as considerably distinct due to
their anisotropic and non-homogenous properties. The delamination is a major factor that deteriorates the
quality of drilling of chopped glass fiber reinforced polyester composites. Delamination reduces the structural
integrity of the material, results in poor assembly tolerances and has the potential for long term performance
deterioration. Surface roughness is also an important aspect of drilling fiber reinforced polyester which can
cause high stress on rivets and bolts, leading to failure. Thus the determination of the parametric settings that
can simultaneously optimize these multiple characteristics in drilling is an important issue to the process
engineers. In this investigation three important input process parameters namely material thickness (t), cutting
velocity (Vc) and feed rate (f) are chosen. A 33 experimental design is used to estimate the Taguchi quality loss
coefficient and assuming that no interaction effect exists, the Taguchi L9 (34) orthogonal design is employed
for multi objective optimization of both the responses, delamination factor (Fd) and average surface roughness
(Ra) with varying weightages, in drilling of glass fiber reinforced polyester composite. To determine the
optimal settings of process parameters multi response signal to noise ratio (MRSN) method is applied.
Confirmation test is further conducted to validate the estimated results.
Keywords: Glass Fiber Reinforced Polyester Composite, Delamination, Multi-characteristics Optimization,
multi response signal to noise ratio (MRSN) method, Quality Loss Function
Investigation of Ionic Liquids as Metalworking Fluids in Minimum Quantity Lubrication
Machining of AISI 1045 Steel
Goindi G. S.1, Chavan S. N.2, Mandal D.3, Sarkar P.4 and Jayal A. D.5*
1
School of Mechanical, Materials and Energy Engineering, IIT Ropar, Rupnagar, 140001,
2
Department of Chemistry, IIT Ropar, Rupnagar, 140001,
3
Department of Chemistry, IIT Ropar, Rupnagar, 140001,
4
School of Mechanical, Materials and Energy Engineering, IIT Ropar, Rupnagar, 140001,
5
*School of Mechanical, Materials and Energy Engineering, IIT Ropar, Rupnagar, 140001, EMail:[email protected]
The necessity of focusing on sustainable manufacturing is now well recognized. Machining is a key
manufacturing process in which the most major sustainability issue is the profligate use of metalworking fluids
(MWFs), leading to significant research in dry, as well as near-dry or minimum quantity lubrication (MQL),
machining. This paper presents the results of a preliminary study in which ionic liquids, a promising and
relatively new family of environment friendly green chemicals, were applied as the lubricating medium in
MQL mode during interrupted orthogonal cutting of AISI 1045 steel under finish machining conditions using
uncoated cemented tungsten carbide tools. Three candidate ionic liquids employing the 1-methyl 3butylimidazolium cation were used as additives with vegetable oil during MQL machining and their effects on
measured machining forces and workpiece surface roughness were compared with the base conditions of dry,
flood-cooled and air-jet assisted machining. The results demonstrate that ionic liquids can significantly
influence the tribology of the machining process when used as additives with vegetable oil during MQL
machining.
Keywords: Dry machining, MQL machining, Ionic Liquids, Lubricants
Mathematical Modeling and Statistical Analysis of Delamination in the Drilling of
Particle Board Wood Composite
J.Lilly Mercy1*, S.Prakash2, Kaushik Goswami3 and P. Vijayalakshmi4
1*
Sathyabama University, Chennai-600119,
2
3
4
Particle board is a wood composite which is cheapest alternative for fiber boards and plywood in furniture
industry. During drilling, the layers of fibers peel out and get detached from its adjacent layers posing severe
threat to the strength of the material and quality of the drilled hole which is referred as delamination. This
article aims to study the effect of various drilling parameters and its interaction effects on delamination during
drilling. Experiments were conducted by varying the drilling parameters and the output response delamination
is modeled mathematically. The adequacy of the mathematical model is analyzed statistically using ANOVA
which gives a high degree of correlation between the input parameters and output response. It is evident that
feed rate during drilling is the most influencing factor to delamination. The results obtained through
experiments were further analyzed and confirmed by microscopic studies through Scanning Electron
Microscope (SEM).
Keywords: ANOVA, drilling, delamination, particle board
Comparison of PVD Coated and Uncoated Carbide Tools While Dry Machining of
Aluminium Alloy – 6063
Ashok Kumar, U.1, Saidulu, N.2 and Laxminarayana, P.3
1, 2, 3
Dept., of Mechanical Engineering, University College of Engineering,
Osmania University, Hyderabad - 500007, INDIA
E-Mail1:[email protected], E-Mail2:[email protected],
E-Mail3:[email protected]
Nowadays, there are many type of cutting tools invented by manufacture engineers to overcome the problem.
So the present work is focused on the analysis of optimum cutting conditions to get highest material rate and
lowest Surface Roughness for both PVD coated carbide and uncoated carbide tool while dry machining of AA
6063.Experiment was designed using Taguchi method with L9 Array for individual tool materials on
workpiece material and the results are analyzed using analysis of variance (ANOVA) method. The
experimental and predicted values are compared. The results shown that the PVD coated carbide tools have
better performance characters compared to the uncoated carbide tools.
Keywords: PVD coated carbide tools, uncoated carbide tools, Taguchi, ANOVA
Friction Surfacing Process of Aluminum Alloys
1, 2,
Ashok Kumar, U.1 and Laxminarayana, P.2
Dept., of Mechanical Engineering, University College of Engineering,
Osmania University, Hyderabad - 500007, INDIA
E-Mail1:[email protected], E-Mail2:[email protected]
In order to improve more environmental friendly and energy efficient alternatives to fusion-based welding and
cladding processes, Friction surfacing process, had been successfully developed over the past decade. The
process is used for corrosion and wear resistant coatings and for reclamation of worn engineering components.
The major requirement is for flexibility to enable rapid changes of process parameters in order to develop new
applications, with variations of materials and geometries in term of cost and reliable manner. So, the present
work deals with the solid state coating by friction surfacing process of various materials coated over substrate
materials. The effects of traverse speed on the geometry, interfacial bond characteristics and mechanical
properties of coatings are studied. Metallurgical studies were made using optical microscopy; mechanical tests
included shear tests, bend tests and micro hardness tests.
Keywords: Friction surfacing, Tool profile, Bend test, Microstructure, Microhardness
Comparison of Dimensional Repeatability and Accuracy for Deformation Machining
Stretching Mode with Sheet Metal Components
Arshpreet Singh1 and Anupam Agrawal2*
School of Mechanical, Materials and Energy Engineering, Indian Institute of Technology Ropar, Rupnagar140001, India.
E-Mail1:[email protected],
E-Mail2*: [email protected]
In the present work a comparative study of dimensional repeatability and accuracy for deformation machining
stretching mode and sheet metal components has been performed. Deformation machining enables the creation
of complex structures and geometries, which would rather be difficult or sometimes impossible to
manufacture. This process allows the creation of monolithic components with novel geometries which were
earlier assembled.Experimental studies have been performed for parts created by the DM ‘stretching mode’
process, in which a thin horizontal floor is machined on the part through high speed machining, and then
incrementally formed into a conical frustum with a single point forming tool.Ten similar components were
fabricated by DM stretching mode, single point increment forming and conventional stretch forming. These
components were measured at various forming depths using a coordinate measuring machine (CMM) and the
dimensional repeatability of these processes was compared.The dimensional repeatability of the DM stretching
mode components largely depends upon the accuracy of the machined floor. Other factors influencing the
repeatability of the process are residual stresses generated during machining, elastic deformation, spring back
and highly localised yielding.
Keywords: Deformation machining, single point increment forming, thin structure machining
Experimental Investigations of Surface Texture in Conventional and Modulation Assisted
Drilling of Stainless Steel 316
1,2
Ravinder Singh Joshi1* and Harpreet Singh2
School of Mechanical, Materials and Energy Engineering, Indian Institute of Technology Ropar, Rupnagar140001, India,
E-Mail1*:[email protected],
E-Mail2)[email protected]
Aim of the present study is to evaluate the effect of conventional and modulation assisted drilling on surface
quality of the hole. The drilling experiments were carried out using uncoated cemented carbide drills on a CNC
lathe machine. A specially available tool holder (TriboMAM) was used for modulation assisted drilling. After
drilling the samples were cut from the centre to examine quality of the hole surface produced using
conventional and modulation assisted drilling. Talysurf roughness tester was used for surface roughness
measurements. Sample length was set at 5mm with a cut-off length of 0.8 mm. Optical microscope was used to
take images of the surface produced using modulation and conventional drilling. It was observed from the
results that the highest surface finish was obtained by modulation assisted drilling at speed of 1500 rpm and
feed 0.04 mm/rev. The worst surface finish was produced with conventional drilling at speed of 1500 rpm and
feed 0.06 mm/rev. Modulation assisted drilling outperformed conventional drilling at almost every feed and
speed combinations.
Keywords: Modulation assisted drilling; Stainless steel 316; Surface roughness
Modeling of GD&T Requirements of Crankshaft Flange Using DOE
Jayalakshmi1*, P.M George2 and S.P Joshi3
Birla Vishvakarma Mahavidyalaya, V.V.Nagar-388120, Gujarat
2
Birla Vishvakarma Mahavidyalaya, V.V.Nagar-388120, Gujarat,
3
Birla Vishvakarma Mahavidyalaya, V.V.Nagar-388120, Gujarat
1*
Crankshaft flange is machined with high degree of accuracy. Geometrical accuracies if not met, will cause
wear, unbalance and vibration, leading to poor functionality of the crankshaft-flywheel assembly. The amount
of variation thus needs to be more strictly defined for accurately machined components. Geometric
dimensioning and tolerancing (GD&T) definition provides the precision to component parts, allowing
economic manufacturing. The crankshaft flange is evaluated for geometric tolerances- roundness and
concentricity. A two level three factor factorial model is designed and data is analyzed using Minitab 16
software to identify the order of significance of operating parameter amongjob speed, feed and depth of cut on
roundness and concentricity. The significant factors, regression model, surface plots and the physical
interpretation of the effects of operating parameters on roundness and concentricity are presented in this
research. The developed models could be used by processing engineers to select the optimum values of
variables to meet the said GD&T requirements
Keywords: Crankshaft, Flywheel, Geometric tolerances
Modeling and Optimization of Surface Roughness in Surface Grinding of SIC Advanced
Ceramic Material
Binu Thomas1, Eby David2 and Manu R3*,
1
MED,NIT,Calicut,673601,E-Mail:[email protected]
2
3*
Advanced ceramics are increasingly utilized in various engineering applications such as aerospace, marine,
automobile etc. But hard and abrasive particles in advanced ceramic materials create unusual machining
problems. Machining of advanced ceramics, require tool materials of very high wear resistance because of the
presence of hard abrasive particles. Grinding is commonly used for producing parts of high precision and high
surface quality from advanced ceramics. But only a few investigations were carried out on grinding of advanced
ceramics till date. The objective of this work is to model and optimize surface roughness of Silicon carbide (SiC)
advanced ceramic material subjected to surface grinding process. In the present work,an analytical model for surface
roughness (Ra) in surface grinding of SiC advanced ceramic material is proposed. Effectiveness of this model is
evaluated by comparison with the experimental results. Finally optimization of surface roughness is done by
considering machining parameters like table feedrate, depth of cut and wheel speed using Response Surface
Methodology in Design Expert software.
Keywords: Advanced Ceramics, Surface Roughness, Response Surface Methodology, Design expert
Investigation of Surface Textured Cutting Tools for Sustainable Machining
1
S. B.Dhage1, P.Sarkar2 and A. D.Jayal3*
School of Mechanical, Materials and Energy Engineering, IIT Ropar, Nangal Road, Rupnagar, PB 140001,
India, E-Mail:[email protected]
2
School of Mechanical, Materials and Energy Engineering, IIT Ropar, Nangal Road, Rupnagar, PB 140001,
3
*School of Mechanical, Materials and Energy Engineering, IIT Ropar, Nangal Road, Rupnagar, PB 140001,
The profligate use of cutting fluids in machining causes serious health issues for operators; additionally, there
are increasing economic and environmental costs associated with managing cutting fluid systems. To improve
the sustainability of machining processes researchers are making efforts to eliminate or reduce the use of
cutting fluids during machining through several means: development of improved tool coatings, materials and
cutting fluids, hybrid machining processes, process optimization, etc. More recently, some researchers have
studied the application of controlled surface micro textures on cutting tool surfaces to improve machining
performance through alteration of tribological conditions at the tool-chip and tool-workpiece interfaces. This
paper presents the results of an experimental investigation involving dry and near-dry intermittent orthogonal
cutting of AISI 1045 steel using uncoated P30 grade cemented tungsten carbide cutting tools with various
surface textures applied on the cutting tools’ rake surfaces via grinding. The results show the significant effects
of the cutting tool’ s rake surface roughness on machining forces and surface roughness of workpieces. Based
on the observed trends some areas for further research in cutting tool development are identified.
Keywords: Dry machining, Near-dry machining, Cutting tool, Surface texture
An Experimental Investigation on Drilling of CFRP/Ti Stacks Using Minimal Flow
Lubricating- (MFL) Technique Using Coated (TiAlN) and Uncoated Drills
1
SenthilKumar, M., 2* Prabukarthi, A. and 3Krishnaraj, V.
Department of Production Engineering, PSG College of Technology, Coimbatore-641004
2*
Department of Mechanical Engineering, PSG College of Technology, Coimbatore-641004
3
Department of Production Engineering, PSG College of Technology, Coimbatore-641004
1
Carbon Fibre Reinforce Plastics (CFRP) and Titanium alloy( Ti6Al4V) were stacked together in aircraft
frames and structure for it high strength to weight ratio and the honey comb structure were replaced by the
stacked material, since the honey comb structure observes moister which is been used for the wing frame for
the defence aircraft. Most of the aircraft structure and frames were manufactured to near net shape but still few
machining process like drilling were done to help in assembling various parts. Majority of the drilling process
were done under dry condition which cause rapid cutting tool wear and increases friction between the tool and
workpiece. The cutting tool manufacturer introduced various drilling to address these issue with through
coolant hole in the drill bit under near dry condition which can be classified into two types minimal flow
lubrication and minimal quantity lubrication. Less research outcome were available in the study of machining
under minimal quantity lubrication condition. The outcome of the researchers in the area of drilling states that
palm oil out performed synthetic oil with respect to reducing the flank wear and corner wear. In this paper an
experimental investigation has been presented on drilling of stacks using palm oil as lubricant under MFL
condition. Two types of drill bit of ø 5 mm was used for the study. Temperature was also measured during the
exit of Ti alloy with the help of K type thermocouple. Maximum Thrust forces of 960N was observed at higher
feed rates (0.15 mm/rev). Maximum Delamination factor (DF) was observed as 2.31 for higher feed rate (0.15
mm/rev); temperature at the exits of Ti alloy increased to 214°C at higher feed rate (0.15 mm/rev) ; Maximum
burr height of 1.9 mm was formed at higher feed rate (0.15 mm/rev).
Keywords: Drilling, CFRP/Ti6Al4Vstacks, minimal flow lubrication, palm oil
Optimisation of Hard Turning of M42 Tool Steel Using PCR-Topsis Method
Sagar P. Bhise1, P.D. Pantanwane2 and Rajiv B.3*
1,2,3*
1
College of Engineering, Pune-411005;
E-Mail:[email protected], 2E-Mail:[email protected], 3*E-Mail:[email protected]
In the recent past hard turning of material is gaining more and more importance owing to versatility of hard
material to be used as cutting tools & for many applications where high life expectancy of components
demand. Hard turn material has the peculiar property to withstand high stress, fatigue resistance, excellent
wear & corrosion resistance. Present study demonstrate the hard turning of M42 tool steel having hardness (5863 HRc) using Cubic Boron Nitride(CBN) (CNGA 120408 S01020 MT KB9610) & coated carbide tool having
standard (CNMG 120408 TN2000). Experiments have been carried out using Taguchi L18 Orthogonal array to
study the statistical significance of input parameters viz. Speed, Feed & Depth of cut. Three responses viz.
Surface finish, Cylindricity & Machining time have been measured and statistically modeled using Taguchi
method. The multiattribute decision making for the responses have been carried out using PCR-TOPSIS
(Process Capability Ratio-Technique for Order Preference by Similarity to Ideal Solution). The proposed
model is useful in selection of process variable for the hard turning material. The result is validated and found
to be satisfactory.
Keyword: Hard turning, CBN & coated carbide tool, M42 steel, PCR-TOPSIS.
Experimental Investigation on Cutting Force and Surface Roughness in Machining of
Hardened AISI 52100 Steel Using CBN Tool
Sudhansu Ranjan Das1*, Debabrata Dhupal2 and Amaresh Kumar3
1*
Department of Manufacturing Engineering, NIT, Jamshedpur, 831014,
2
Department of Production Engineering, VSSUT, Burla, 768018,
3
Department of Manufacturing Engineering, NIT, Jamshedpur, 831014,
In the present study, an attempt has been made to investigate the effect of cutting parameters(cuttingspeed,feed
anddepthofcut) on the performance characteristics (cuttingforce and surface roughness)in finish hard turning of
AISI 52100 bearing steel with CBN tool. The combined effects of the process parameters on t wo performance
characteristics are investigated employing Taguchi’ s L9 orthogonal array and analysis of
variance(ANOVA).The results show that feed rate and cutting speed strongly influence surface roughness.
However,the depth of cut is the principal factor affecting cutting force, followed by feed. The experimental data
were further analyzed to predict the optimal range of cutting force and surface roughness and to correlate
between cutting parameters and performance characteristics using multiple linear regression analysis. Finally
the wear surface of the tool and machined surface of the workpiece were examined under optimal cutting
conditions (v = 200 m/min, f = 0.08 mm/rev and d = 0.2 mm) using optical microscope and scanning electron
microscope (SEM) respectively.
Keywords: AISI 52100 steel, CBN tool, Cutting force, Surface roughness.
Optimization of Machining Parameters during End Milling of GFRP Composites by
Desirability Function Analysis using Taguchi Technique
Reddy Sreenivasulu
R.V.R. & J.C.College of Engineering (A), Guntur, Andhra Pradesh, INDIA – 522019
This paper presents a new approach for optimizing the machining parameters on milling of glass-fibrereinforced plastic (GFRP) composites. Optimization of machining parameters was done by an analysis called
desirability function analysis (DFA), which is a useful tool for optimizing multi-response problems. In this
work, based on Taguchi’ s L9 orthogonal array, milling experiments were conducted for hand layup GFRP
composites of randomly oriented long fibers using K10 grade carbide cutting tool. The machining parameters
such as cutting speed, feed rate and depth of cut are optimized by multi-response considerations namely
surface roughness average, delamination damage factor. A composite desirability value is obtained for the
multi-responses using individual desirability values, based upon that value, the optimum levels of parameters
have been identified and significant contribution of parameters were determined by analysis of variance
(ANOVA). Confirmation test was conducted to validate the test result, which shows that, surface roughness is
improved from 6.188 to 4.52 m and the delamination damage factor is greatly reduced from 1.68 mm/mm to
1.19 mm/mm. It is clearly shown that multiple performance characteristics in the GFRP machining process are
greatly improved through this study. Thus, the application of desirability function analysis integrated with
taguchi technique proves to be an effective tool for optimizing multi response characteristics of machining
parameters during end milling of GFRP composites.
Keywords: GFRP, Desirability function analysis, Surface roughness, Delamination damage
Optimization of Material Removal Rate and Surface Roughness in WED-Machining of TiNi SMA Using
Grey Relation Analysis
Manjaiah M1*, Narendranath S2 and Basavarajappa S3
Dept. of Mechanical Engineering, NITK, Surathkal, 575025,
2
Dept. of Mechanical Engineering, NITK, Surathkal, 575025,
3
Dept. of Mechanical Engineering, UBDT college of Engg., Davangere, 577004,
1*
In the present paper, wire electro discharge machining (WEDM) of TiNi shape memory alloy (SMA) is
studied. Influence of pulse on time, pulse off time, servo voltage, dielectric fluid pressure and wire speed are
investigated for material removal rate (MRR) and surface roughness (Ra) during machining of a stepped TiNi
beam. To optimize the MRR and Ra simultaneously, grey relational analysis (GRA) is employed with Taguchi
L27 orthogonal array. Through GRA, grey relation grade is used as performance index to find the optimal
process parameters for the machining characteristics (MRR and Ra). Analysis of variance (ANOVA) shows
that the pulse on time is the most significant parameter affecting the MRR and Ra. Confirmation results proves
the potential of GRA to optimize the multi machining characteristics of WEDM process parameters.
Keywords:WEDM,TiNi SMA, MRR, Ra, Multi optimization, GRA, L27 Orthogonal array
Cryogenic Machining of SS304 Steel
Sunil Magadum1*, Arun Kumar S2, Yoganath V.G3 and C.K.Srinivasa4
Central Manufacturing Technology Institute, Bangalore-560022
1
*E-mail: [email protected],2E-mail: [email protected],
3
E-mail: [email protected](4E-mail: [email protected]
Cryogenic coolants as cutting fluids are gaining importance as they are eco-friendly, recyclable and moreover
they do not produce any harmful by-products. Liquid nitrogen at -196º C is commonly used coolant in
cryogenic machining. In the present work machining of SS304 was carried out on a lathe using coated carbide
tool with cryogenic and flood coolants. Tests were carried out at cutting speed of 200 and 250 m/min, and the
feed rate, depth of cut was kept constant at 0.2 mm/rev and 1.5 mm respectively. Coated carbide CNMG
120404 Insert was used as a cutting tool. Tool wear, tool life and cutting forces were measured. The results
have revealed that cryogenic machining has yielded better tool life as compared to conventional flood
machining.
Keywords: cryogenic machining; tool wear; tool life; cutting forces; coated carbide tool
Role of MQL and Nano Fluids on the Machining of Nicrofer C263
P Subhash Chandra Bose1*, C S P Rao2 and Kishore Jawale3
National Institute of Technology, Warangal, 506004, E.Mail:[email protected]
2
National Institute of Technology, Warangal, 506004,E.Mail:[email protected]
3
National Institute of Technology, Warangal, 506004,E.Mail:[email protected]
1*
Minimum Quantity Lubrication (MQL) is a very good tradeoff between over-use of cutting fluids and poor
surface integrity obtained by dry machining. MQL provides eco friendly machining environment and improves
machinability characteristics. Nanofluids have novel properties that make them potentially useful in heat
transfer medium in cutting zone. This paper presents the effect of MQL and Nanofluids with 1% volume of
Al2O3 and 4% volume Al2O3 on the machinability characteristics of Nicrofer C263 mainly with respect to
Surface Roughness, Cutting Forces and Temperature dissipation. Experimental analysis for three different
conditions – dry, MQL and MQL + Al2O3 Nanoparticles are carried out. It was found that use of combination
of Nanofluids and MQL gives better surface finish with good temperature dissipation in cutting zone when
compared with other conditions. It is also observed that there is a decrease in cutting forces and which may
lead to reduced tool wear.
Keyword: Nano Fluids, MQL, Super alloys, machining
Multi Response Optimization of Machining Parameters in High Speed Machining of YZTA Insert Using Desirability Function Approach of Response Surface Methodology
(RSM)
1*
2
1
Mandal, Nilrudra., Doloi, B. and Mondal, B.
1
Centre for Advanced Materials Processing,
CSIR-Central Mechanical Engineering Research Institute, Mahatma Gandhi Avenue,
Durgapur-713209, India
2
Production Engineering Department, Jadavpur University, Kolkata,India
* E-Mail:[email protected]
An attempt has been made to apply the multi response optimization using desirability function concept for
optimizing the cutting conditions (cutting speed, feed rate and depth of cut) on machining responses i.e. flank wear,
cutting force, surface roughness and chip reduction coefficient while finish turning of AISI 4340 steel using
developed yttria based Zirconia Toughened Alumina (ZTA) inserts. These ZTA inserts were prepared through wet
chemical co precipitation route followed by powder metallurgy process. The machining performance of the insert
has been evaluated using NH 26 lathe installed in the laboratory with different condition as per Central Composite
Design of Response Surface Methodology. The mathematical models for each response have been developed using
second order regression analysis. Key parameters and their interactive effect on each response have also been
presented in graphical contours. The optimization of parameters has been done for machining with this non
conventional cutting inserts using the desirability function concept with a target of high cutting speed and high feed
rate. The aim is to minimize the responses i.e. flank wear, cutting force, surface roughness and chip reduction
coefficient. Using the criteria, the optimum condition has been arrived with a cutting speed of 380 m/min, feed rate
of 0.24 mm/rev and depth of cut of 0.5 mm. Using the same cutting speed and feed condition, the desirability
function values of flank wear, cutting force, surface roughness and chip reduction coefficient comes around 71%,
90%, 95% and 93%.
Keywords: Zirconia toughened alumina (ZTA). Y-PSZ, transformation toughening, ceramic insert
An Experimental Investigation of Hot Machining Performance Parameters using OxyAcetylene Gas Setup
Venkatesh Ganta1* and D. Chakradhar2
Dept. of Mechanical Engg., NITK Surathkal, 575025, E-Mail:[email protected]
2
Dept. of Mechanical Engg., NITK Surathkal, 575025, E-Mail:[email protected]
1*
This paper focuses on optimizing the cutting conditions for the average surface roughness (Ra) and metal
removal rate (MRR) obtained in hot machining of 15-5PH martensitic stainless steel with 40 HRC. Hot
machining experiments were performed on lathe machine using K313 carbide tool insert. Experiments were
conducted based on Taguchi L18 orthogonal array. The statistical method of signal-to-noise (S/N) ratio and
the analysis of variance (ANOVA) were employed to investigate the optimum process parameters like speed
feed, depth of cut and workpiece temperature and their effect on the performance characteristics i.e., surface
roughness and metal removal rate. The results of the study indicate that feed rate has the most significant effect
on surface roughness. Cutting speed and feed rate has the most significant effect on material removal rate.
Keywords : Hot machining, Surface roughness, MRR, Taguchi
Investigation on the Influence of Cutting Parameters on Machine Tool Vibration and
Surface Finish using MEMS Accelerometer in High Precision CNC Milling Machine
N.Kusuma1*, Megha Agrawal2 and P.V.Shashikumar3
Central Manufacturing Technology Institute, Bangalore-560022, India,
1
E-Mail:[email protected],2E-Mail:[email protected],3E-Mail:[email protected]
The purpose of this research is to investigate on the influences of cutting parameters on machine tool vibration
& surface finish using MEMS Accelerometer in high precision CNC milling machine. The cutting parameters
considered are depth of cut, feed rate and spindle speed. In this work, efforts has been made to acquire
vibration data on spindle housing using MEMS Accelerometer, measure surface finish and analyse the
influence of cutting parameters on machine tool vibration and surface finish using ANOVA technique and also
predict the surface roughness using ANN. Here the ANOVA results for full factorial and taguchi design of
experiments techniques has been compared and found that taguchi design of experiment is better and reliable
to obtain optimal number of experiments. Further the cutting parameters are optimised using genetic algorithm
approach, which are required to be sent to CNC machine to improve the surface roughness and control
vibration.
Keywords: MEMS, Cutting Parameters, ANOVA, Artificial Neural Network (ANN)
Potential of Vegetable Oils as Micro Lubrication / Cooling Medium for SQL- Grinding
1
Manoj Kumar K.1, Jeewan Sarda2 and Amitava Ghosh3*
Dept. of Mech. Engg., IIT Madras, E-Mail:[email protected]
2
Dept of Mech. Engg., IIT Madras, E-Mail: [email protected]
3*
Dept. of Mech. Engg., IIT Madras, E-Mail: [email protected]
Scope and effectiveness of using vegetable oils as an environment friendly small quantity lubrication (SQL)
medium have been investigated in the present work, where hardened AISI 52100 steel was ground by an
alumina wheel in plunge mode. Palm oil and sunflower oil, which are two easily available vegetable oils in
Indian market, were selected and characterized for wetting capability and lubricity. Sunflower oil was found to
outperform its counter part and synthetic soluble oil in producing good wetting and effective lubrication on
alumina and steel surface. Further grinding experiments were carried out to evaluate performance of the
vegetable oils and the same was compared with that of conventional soluble oil. Performance was analysed in
terms of grinding force, surface roughness and G-ratio. Sunflower oil was found to be the most effective to
reduce grinding force and enhance G-ratio.
Keywords: Metal working fluid (MWF), SQL grinding, Vegetable oils, G-ratio
Performance of MoS2 Spray Coated End Mills in Reduction of Built-Up Edge Formation
(BUE) in Machining Aluminium
Suresh Kannan I1, Sandip Baul2 and Amitava Ghosh3*
1
Dept. of Mech. Engg. , IIT Madras, Chennai, 600036,E-Mail:[email protected]
2
Dept. of Mech. Engg. , IIT Madras, Chennai, 600036, E-Mail:[email protected]
3*
Dept. of Mech. Engg., IIT Madras, Chennai, 600036, E-Mail:[email protected]
Adhesion of chip on cutting tool is a major challenge in dry machining of aluminium. Diamond coated
carbides are recognized as the best performing tools for dry machining of aluminium but highly expensive. In
the present investigation, suitability of a solid lubricant i.e. MoS2 in the form of coating for aluminium
machining was investigated. First the feasibility of application was simulated by wettability test with respect to
uncoated and TiN coated carbide (WC-Co) substrate. A clear indication of its potential was pronounced in
large wetting angle. Further, a set of end mills were spray-coated by MoS2 using an economic technique after
suitable substrate modification. Significant improvement was noticed in terms of adherence of chip on tool,
reduced cutting force, and enhanced surface finish of machined component when MoS2 coated end mills
performed machining operation in place of uncoated and TiN coated tools.
Keywords:Aluminium, Wettability, BUE, MoS2, surface finish
Design and Evaluation of a Novel Machine Bed with Adjustable Pin Configuration to
Minimize Damage during Sheet Metal Cutting Processes
Vijay Anand K. 1* and Ramesh Babu A. 2
Department of Mechanical Engineering, PSG College of Technology, Coimbatore – 641004,
E-Mail1*: [email protected], E-Mail2:[email protected]
In this paper, a novel design of a machine bed is proposed for sheet metal cutting, in order to minimize the
damage caused during Laser, Plasma, and Abrasive Water Jet cutting processes. In contrast to the existing bed
design, that has fixed blades, the proposed bed uses adjustable blades and pins which adaptively change its
position with respect to the layout of the parts. The pins support the sheet during cutting process. These pins
are inserted in the holes which are drilled on the movable blades. The layout of the parts to be cut is laid over
the bed; then blades on the bed are adjusted so that, maximum number of holes provides support to the parts in
the layout. Next, the suitable holes on the blades are identified to insert the pins, so as the tool path is not
overlapping the pins. An algorithm is developed to find out an effective pin configuration with maximum
number of pins to support the parts and minimum pins to overlap the tool path. The performance of the
proposed design and algorithm is demonstrated using a layout generated by typical parts.
Keywords: Sheet metal cutting, Machine bed, Laser cutting, Abrasive Water Jet cutting
Experimental Studies on the Grinding of Ti-6Al-4V using Micro and Nano Size Solid
Lubricants
A. K. Malik1*, S. Ghosh2 and R. K. Pandey3
1
Department of Mechanical Engineering, IIT Delhi, 110016,[email protected]
2
Department of Mechanical Engineering, IIT Delhi, 110016, [email protected]
3
Department of Mechanical Engineering, IIT Delhi, 110016, [email protected]
Ti and its alloys are generally considered as difficult to machine materials. Grinding of these materials liberates
huge heat, which impair the surface integrity of the workpiecein addition to high wear of the grinding
wheel.Therefore, effective cooling and lubrication at the interface of wheel and workpiece are essential
forremoval of interfacial heat.The conventional cooling/lubricating fluids partiallyremove the heat from the
interface due to the “ air barrier” and “ film-boiling” effect at the elevated grinding parameters.Therefore, it is
worth exploringfor eco-friendly and alternative mediums foreffective cooling and lubrication in grinding
process. In this paper, results of an experimentalstudy carried out using micro MoS2, nano graphite and nano hBN powders in place of conventional cooling/lubricating fluid in grinding of Ti-6Al-4V material have been
reported.Based on the tribological investigations, improvement inthe process performance parameters are
observed with the powder lubricants. The nano h-BN powder was found more capable in improving the
tribological properties and surface finish as compared to other two solid lubricants i.e. micro MoS2 and nano
graphite.
Keywords:Powder lubrication, Ti-6Al-4V alloy, SiC disk
Performance Evaluation of TiN Coated and Uncoated Carbide Tools in Turning AISI
4140 Steel
Pratik L. Nagalwade1* and A. V. Kale2
*Department of Mechanical Engineering, Yeshwantrao Chavan College of Engineering, Nagpur-441110,
[email protected]
2
Department of Mechanical Engineering, Yeshwantrao Chavan College of Engineering, Nagpur-441110,
[email protected]
1
Tool wear is one of the most important aspects in metal cutting, especially when machining hardened steels.
The present work shows the results of tool wear and surface finish obtained from the turning operation on
hardened AISI 4140 using TiN coated and uncoated edges. Machining tests were performed under dry cutting
conditions by varying cutting speeds and feeds. The effect of cutting speed and feed rate on tool wear (tool
life) and surface roughness of the TiN coated carbide inserts was experimented. For coated tools the tool life
obtained was relatively higher values. For comparison, uncoated tool was also tested under the similar cutting
conditions. The surface roughness of the work pieces were found out using Taylor Hobson Surface Roughness
Tester. Turning with coated tool is more economical than the uncoated in terms of energy and power
requirements. Results show that the tool life is influenced principally by the depth of cut and on the other hand,
both feed rate and workpiece hardness have statistical significance on surface roughness. Stresses occurring on
nose of the coated as well as uncoated inserts were checked using ANSYS analysis.
Keywords: Speed, Feed, Depth of Cut, Surface Roughness
Finite Element Analysis of Workpiece Temperature during Surface Grinding of Inconel 718 Alloy
Chahat Sharma1, Sudarsan Ghosh2 and Prabal Talukdar3
Department of Mechanical Engineering, IIT Delhi, New Delhi, India
1
Email:[email protected],2E-Mail: [email protected],3E-Mail: [email protected]
1,2,3
This paper presents an approach for development of a three dimensional model to find out the temperature
variation during grinding of Inconel 718 material. Model is developed using finite element analysis. Method of
discretization is used to find out transient temperature variation. In this time step and sub step method is used
for loading the movable heat source. Model is developed using FEM software ANSYS and then compared to
the experimentally measured values using embedded thermocouple method.
Keywords: Inconel 718, Temperature, Grinding, Finite element method
Comparative Evaluations of Tool Nose Wear Progression under Dry and Near-Dry
Cutting Conditions during Hard Turning through Experimentation and Mathematical
Modeling
Satish Chinchanikar1* and S.K. Choudhury2
1*
Vishwakarma Institute of Information Technology, Pune-48, India,
2
Indian Institute of Technology Kanpur, Kanpur-208016, India,
In present work, attempts have been made to compare the tool nose wear progression under dry and near-dry
(minimum quantity lubrication) cutting conditions through experimentation and mathematical modeling in
view of disagreement of the researchers about the use of coolants in hard turning. Experiments on hardened
AISI 4340 steel (55 HRC) were performed using PVD-applied TiAlSiN coated carbide inserts varying the
cutting speed and feed in the wide range of cutting conditions and at constant depth of cut of 0.3 mm.
Mathematical models which could be used to predict tool nose wear progressions with machining time under
dry and near-dry cutting conditions were developed based on experimental data. Near-dry cutting experiments
were performed using a mist formed by a very small quantity of oil (S40) of 60 ml/hr and compressed air at
pressure of 5 bar. It has been observed that tool nose wear progressions are prominently gets affected with
cutting speed in comparison to feed. However, this effect has been observed to be more prominent when
machining under dry cutting conditions. Higher tool life obtained under near-dry cutting conditions can be
attributed to lower cutting temperatures and better evacuation of chips during machining. However, at lower
cutting speed, no significant difference in tool nose wear progression has been observed under dry and near-dry
cutting conditions. Coefficient of correlations of developed mathematical models found close to 1, which
shows that the models could be used to predict reliably tool nose wear progressions within domain of the
cutting parameters selected under dry and near-dry cutting conditions using PVD-applied TiAlSiN coated
carbide tool.
Keywords: Tool wear, Dry and Near-dry cutting, Mathematical modeling, Hard turning
FEM Analysis on Residual Stresses induced in Dry Turning: A Review
A.K. Mishra1 and P. Shandilya2
MNNIT, Allahabad, 211004, E-Mail:[email protected]
2
MNNIT, Allahabad, 211004, E-Mail:[email protected]
1
In present scenario dry turning is very interesting topic for researchers and much research is going on different
areas of it. Surface integrity is very essential parameter during dry turning process. In this paper many aspects
of surface integrity are discussed with more focus on residual stress. In case study residual stresses are
calculated experimentally by X-ray diffraction technique as well as predicted by finite element method for Ti–
6Al–4V titanium alloy. Then a comparison is made between the experimental value and predicted value by
finite element model. The effect of coated and uncoated tool at different cutting parameter is discussed. In
recent days more work is going on residual stress with Ti–6Al–4V titanium alloy for its critical application.
Keyword: Residual Stresses, Ti-6Al-4V Titanium alloy, Finite element method
Performance Evaluation of Ordinary and Wiper Inserts in Dry Turning of Inconel 718
Super Alloy using Grey-Fuzzy Algorithm – A Hybrid Approach
K.Venkatesan1, R.Ramanujam1*, Vimal Saxena1 and Rachit Pandey1
School of Mechanical and Building Sciences, VIT University, Vellore, India – 632 014.
* E-Mail:: [email protected]
The superior thermo-mechanical properties of Inconel 718 super alloy make it suitable for high end
temperature applications such as aerospace, nuclear, chemical and petrochemical industries. Even though these
properties are desirable from design perspective but they put constraints on machining while achieving end
products. Characteristics such as retaining of high strength at elevated temperature, work hardening during
machining and its ability to weld and form built-up edge are few of the challenges and hence these alloys are
designated as “ difficult-to-cut” materials. In the past decade, many researches have been conducted to analyze
the machinability of Inconel 718 alloy by varying the cutting conditions (speed, feed and depth of cut), cutting
tool materials and tool geometry. Still there is need for continuing research for achieving improved
machinability with new generation wiper cutting inserts at optimal setting of cutting conditions. The present
work focuses on the performance evaluation of ordinary and wiper inserts on machinability of Inconel 718 by
employing hybrid Grey-Fuzzy approach. The experiments were conducted according to Taguchi’ s L9
experimental design for three different levels of cutting parameters viz cutting speed, feed rate and depth of
cut. Surface roughness and cutting force are chosen as performance characteristics. The obtained results
indicated that coated inserts with wiper geometry performed better in terms of surface roughness within the
designed cutting parameters using Grey-Fuzzy hybrid approach.
Keywords: Inconel 718, Taguchi method, Grey Analysis, Fuzzy inference system
Investigation on Influence of Refrigerated Air and High Heat Transfer Rate MQL in
Turning of Aluminum Metal Matrix Composite
N.V.V.S. Sudheer1*, K.V.J.Rao2 and V.Chittaranjan Das3
R.V.R & J.C. College of Engineering, Guntur, 522 019, E-Mail:[email protected]
2
St.Peters Engineering College, Hyderabad, 500 014, E-Mail:[email protected]
3
R.V.R & J.C. College of Engineering, Guntur, 522 019, E-Mail:[email protected]
This paper presents the experimental investigation of cutting conditions on surface roughness during turning of
Aluminium Silicon Carbide Metal Matrix Composite (Al/SiC – MMC) in the environments of pressurized
1*
refrigerated air and high heat transfer rate Propylene glycol minimum quantity lubricant (MQL) and compared
with dry cutting. A full factorial 33 design was employed to conduct experiments. The Mathematical model
was developed by using Multiple Regression. From the results it is observed that Aqua propylene glycol
minimum quantity lubricant environment gives better surface finish compared to compressed refrigerated air
and dry environment. The values of Surface roughness in compressed Refrigerated air environment are in
between Propylene Glycol MQL environment and dry environment.
Keywords: MMC, Refrigerated Air, High Heat Transfer MQL, Multiple Regression, ANOVA.
Correlation among the Cutting Parameters, Surface Roughness and Cutting Forces in
Turning Process by Experimental Studies
Jithin Babu R.1 and A. Ramesh Babu2
1
PSG College of Technology, Coimbatore,641004,[email protected]
2
PSG College of Technology, Coimbatore,641004,[email protected]
In this work experimental investigations and statistical analysis are carried out to study the effect of cutting
parameters (cutting speed, feed rate, and depth of cut) on surface roughness and cutting forces during dry
turning of aluminium alloy. Full factorial design of experiments corresponding to 27 runs (33) was followed for
the experimental design. The contribution of each factor on the output is determined by analysis of variance.
During analysis it is found that feed rate is the most influencing parameter affecting surface roughness
(70.35%). Depth of cut (85.37%) was the most influencing parameter on the cutting forces. Later prediction
models were created using second order multiple regression method. The model provided good prediction
accuracy with a mean absolute error of 3.47% for surface roughness and 6.8 % for the cutting forces. In order
to validate the regression model, another prediction tool using artificial neural network (ANN) is proposed. It
is clearly seen that the proposed model is capable of predicting the surface roughness and cutting forces with
good accuracy. The statistical analysis, multiple regression modeling and neural network prediction were
performed on MINITAB 16 and MATLAB nntoolbox.
Keywords: surface roughness, ANOVA, ANN.
Experimental Investigation and Analysis of Machining Characteristics in Drilling Hybrid
Glass-Sisal-Jute Fiber Reinforced Polymer Composites
M. Ramesh1*, K. Palanikumar2 and K. Hemachandra Reddy3
1
Department of Mechanical Engineering, Sri Sai Ram Engineering College,
Chennai-600044, Tamil Nadu, India. E-Mail:[email protected].
2
Department of Mechanical Engineering, Sri Sai Ram Institute of Technology,
Chennai-600044, Tamil Nadu, India. E-Mail:[email protected].
3
Department of Mechanical Engineering, Jawaharlal Nehru Technological University Anantapur,
Anantapuramu-515002, Andhra Pradesh, India. E-Mail:[email protected]
In the highly competitive manufacturing world, the ultimate goals of the manufacturer are to produce high
quality products at minimum cost and in less time. The use of composite materials is growing at a fast rate,
because these materials have many constituents and each has its own unique characteristics. While focusing on
the composite materials, the main points to be considered are environment friendliness and light weight, with
high specific properties. To fulfil these requirements, the natural fibers are incorporated into manmade fibers,
and partially eco-friendly hybrid composites have been developed by using glass, sisal and jute fibers as
reinforcing material in the polymer resin matrix. The drilling of composite materials is difficult when
compared to metals, because the tool has to pass alternately through the matrix and reinforcement, which have
different properties. In this experiment, drilling is carried out in an auto feed drilling machine, attached with a
multi component piezo-electric dynamometer, by using a coated carbide drill. The aim of this work is to
emphasize the machining characteristics of the hybrid composites by varying the cutting speed, feed rate and
tool diameter. The drilling induced damage is analyzed with the help of the profile projector, and the cutting
edges of the drilled holes are examined, by using the scanning electron microscopy (SEM) analysis. From the
results it has been observed, that all the above said parameters affect the drilling process, and the induced
damage has been reduced by varying the feed rate.
Keywords: Hybrid composites, Thrust force, Torque, Delamination
Empirical Modeling of Cutting Forces in Ball End Milling using Experimental Design
1*
VenkateswaraSarma M.N.M.1* and Manu. R.2
NIT Calicut, 673601, E-Mail:[email protected]
2
NIT Calicut, 673601, E-Mail:[email protected]
Precision parts with curved surfaces such as dies and molds are required in many manufacturing industries.
Ball end milling is one of the most common manufacturing processes for such parts. Force modeling of ballend milling is important for tool life estimation, chatter prediction, tool condition monitoring and to estimate
the tool deflection which affects the quality of the finished parts. This project presents an approach for
modeling the cutting forces acting on ball end mill in milling process. The steps used in developing the model
are based on mechanistic principles of metal cutting. Initially, the forces acting on the ball end mill are
modeled based on the literature, in which the empirical relationships were used to relate the cutting forces to
the undeformed chip geometry.These modeling equations governing the cutting forces are programmed in the
MATLAB software. A series of slot milling experiments are conducted using a ball end mill by varying the
feed and depth of cut and the cutting forces acting on the work piece are measured. An algorithm was
developed, to calculate the empirical parameters, by using the deviation between the average forces measured
while doing experiments and the force values predicted by the software program.
Keywords:Force prediction, ball end mill, Algorithm
Form Error Correction of Bevel Gears by Electrochemical Honing Process
Shaikh Javed Habib1* and Neelesh Kumar Jain2
1*
Department of Mechanical Engineering, RSSOER, JSPM Narhe Technical Campus, Pune (MS), India
2
Discipline of Mechanical Engineering, Indian Institute of Technology Indore (India),
This paper reports about the correction of form errors of case hardened straight bevel gears (made of 20MnCr5
alloy steel) by the Electrochemical honing (ECH) process using the honing gear made of 20MnCr5 alloy steel,
and effects of ECH parameters on the correction of form errors. Surface topography, pitch error and runout
have been used to evaluate the form errors whereas average surface roughness (Ra) and maximum surface
roughness (Rmax) have been used to evaluate the surface finish. An innovative experimental setup has been
designed and developed for ECH of bevel gears based on a novel concept of using a set of twin complementary
cathode gears. In this, one of the cathode gears has an undercut conducting layer sandwiched between two
insulating layers while, in the other cathode gear, the insulating layer is sandwiched between two undercut
conducting layers. These two complementary cathode gears ensure finishing of the entire face width of the
workpiece gear and at the same time inter-electrode gap required for ECH. The experimental results have
shown significant reduction in the form errors i.e. the quality of the bevel gear has improved from standard
DIN 8 to DIN 7 for the pitch error, from DIN 9 to DIN 8 for the adjacent pitch error and from DIN 7 to DIN 6
for the runout within an optimized finishing time of 2 minutes as well as improvement in surface finish as
Raand Rmax from 1.79 µm and 10.0 µm to 1.09 µm and 8.42 µm respectively for the optimum process
parameters thus ensuring enhanced service life and operating performance.
Keywords: Electrochemical Machining, Honing, Gear, Form
Evaluation and Comparison of Machinability Characteristics of Maraging Steel and AISI
304 Steels
Rangilal, Bhukya1, C.S.P. Rao2 and G.V. Rao3
Department of Mechanical Engineering,National Institute of Technology,Warangal,
506004 - AP. E-Mail:[email protected]
2
Department of Mechanical Engineering,National Institute of Technology,Warangal.
3
Department of Mechanical Engineering,National Institute of Technology,Warangal.
1
Machinability studies on difficulty- to- cut materials, is always a topic of interest for researchers and
practitioners in metal cutting. Maraging steel and AISI 304 steel whose hardness values are 58HRC and
29HRC respectively were conducted for the Machinability studies with TiN coated carbide tools. The
experiments were conducted on a CNC Retrofitted VDF lathe machine. The Cutting force, surface roughness
and temperature have been measured using kistler dynamometer (9272), handy surf (E35B), and Infrared noncontact thermometer (Kiray). The experiments were conducted using Design of experiments (DOE), L27
orthogonal array while machining maraging steel and AISI 304 steel. Minitab16 Software also used for
analyzing the results. The output parameters of experimentation such as cutting force (Fz), surface roughness
(Ra) and temperature (T) have been recorded for varying process parameters like speed, feed, and depth of cut.
Comparison of machinability is also made and presented among two materials i.e Maraging steel and AISI 304
steels .It was found that Maraging steel has got good machinibility characteristics around 75m/min cutting
speed, 0.094mm/rev feed and doc1.5mm depth of cut and
similarly AISI 304 steel has got good
machinibility characteristics around 75m/min cutting speed, 0.094mm/rev feed and doc1.5mm depth of cut.
Keywords: Cutting force, surface roughness, Cutting temperature, dry machining.
Isophote Based Tool Path Planning Strategy for Sculptured Surface CNC Machining
Aniket Anil Chaudhary1* and S.S. Pande2
Computer Aided Manufacturing Laboratory, Department of Mechanical Engineering, Indian Institute of
Technology Bombay, Powai, Mumbai – 400076, India
E-Mail1*:[email protected], E-Mail2:[email protected]
This paper reports the design and implementation of I-SSM system for machining sculpturedsurfaces on 3 axis
CNC milling machineusing the concept of isophotes. The resulting tool path ensures the CNC part program
restricts scallop height below the user specified value. CAD model in STL format is input to the
system.Isophotes are generated on it and localized tool path is computed to maintain the scallop height in each
region. An efficient method of stitching of tool path into a single unified tool path has been implemented. The
system has been tested, validated and compared with commercial software to show case its ability to
adaptively generate the tool path to control the scallop height during finishing
Keywords: Isophote, Sculptured Surface Machining, 3-Axis CNC, Tool Path Planning
Behaviour of Cutting Forces in Hard Turning Considering Effect of Tool Wear on
Principal Flank, Auxiliary Flank and Rake Faces: Individually and in Combination
Amarjit Prakashrao Kene1* and S. K. Choudhury2
Indian Institute of Technology Kanpur, Kanpur, 208016,
1*
E-Mail:[email protected], 2E-Mail:[email protected]
1*,2
In the present work behaviour of cutting forces was investigated considering the effect of tool wear on flank
and rake face individually and also in combination. The relationship between cutting forces and wear land was
studied by performing the turning operation on EN24 hardened steel of diameter 70 mm and length 400 mm
using commercially available single layer PVD coated TiSiN-TiAlN nanolayer insert at constant cutting
conditions. In the beginning the inserts were worn out artificially using electric discharge machining process.
From the plot of cutting forces with wear land and experimental results taken individually, it has been observed
that the tangential cutting force was more affected by crater wear. However axial and radial forces observed to
be predominantly affected by principle flank wear. On the other hand, wear on auxiliary flank face showed no
specific effect on any of the forces. Axial and radial forces were observed to be affected mostly when
combination of flank wear and crater wear was considered. The average axial force Fx, tangential force Fz,
radial force Fywere found to be 176.73 N, 225.56 N and 245.84 N respectively in case of no wear (zero wear)
and 165.26 N, 219.27 N and 198.36 N respectively in case of combination of wear.
Keywords: Hard turning, cutting forces, PVD coated insert, Artificial tool wear
Experimental Evaluation and Optimization of Dry Drilling Parameters of AISI304
Austenitic Stainless Steel using Different Twist Drills
Nayan G Kaneriya1* and Gaurav Kumar Sharma2
Mechanical Engineering Department1*, R.K University, Rajkot-360020, India, E-Mail:
[email protected]
Mechanical Engineering Department2, R.K University, Rajkot-360020, India, E-Mail:
[email protected]
AISI 304 austenitic stainless steel is widely used in areas such as buildings, automobile, aircrafts and medical
surgical equipment, but machining of AISI 304 austenitic stainless steel is difficult due to high tensile strength,
high ductility, low heat conductivity and high fracture toughness. The cutting temperature at drill tool-chip
interface affects drill hole quality, lowers tool life, reduces hole finishing and blunt edges of drill tool that
decreases productivity. The main objective of this work is to reduce temperature caused in drill tool while dry
drilling of AISI 304 austenitic stainless steel by optimizing drilling parameters and selecting suitable drill tool
material. The performances of HSS, Cobalt coated HSS and K20 Solid Carbide drill tool were evaluated in
terms of temperature, material removal rate and drill tool life. The performance parameters viz. feed rate and
spindle speed are experimentally investigated to minimize the temperature at drill tool bit. The experiments
were carried out on vertical machining center (VMC 1050) machine equipped with maximum spindle speed of
8000 rpm and 15.8 kW drive motor. VMC part programs were created with ProENGINEER CAD/CAM
software on an Intel IV (1.0 GHz) personal computer. The values of drill tool bit temperatures were measured
using infrared thermometer. The experiments were performed by varying spindle speeds from 1200 rpm to
1500 rpm at constant feed rate 0.05 mm/rev and varying feed rate from 0.05 mm/rev to 0.09 mm/rev for each
drill tool material. Experimental results were simulated with DEFORM 3D software. Drilling parameters like
feed rate and spindle speed were optimized to minimize temperature and to maximize material removal rate
(MRR) using responsesurface methodology (RSM), a multi objective optimization technique.
Keywords: Drilling, AISI 304, Temperature, RSM
Effect of Carburizing Flame and Oxidizing Flame on Surface Roughness in Turning of
Al/SiC MMC and Teaching-Learning-Based Optimization of Process Parameters
1*
N. V. V. S.Sudheer1* and K. Karteeka Pavan2
R.V.R &J.C.College of Engineering, Guntur, 522 019, E-Mail:[email protected]
2
R.V.R &J.C.College of Engineering, Guntur, 522 019, E-Mail:[email protected]
This paper presents an experimental probe into the effects of carburising and oxidising flame on the surface
finish in turning of Aluminium metal matrix composite. The experimental design is performed by using 33 full
factorial designs. From the measured values of surface finish, the effects of different parameters like speed,
feed and depth of cut are estimated. Observation of results proved that carburising flame cutting operation
yields better surface finish compared to dry & oxidising flame cutting. From the measured values the
mathematical power models are developed. These models are subjected to Teaching-Learning-Based
Optimization (TLBO) technique for finding global values of speed, feed, and depth of cut for minimizing
surface roughness and maximizing material removal rate.
Keywords: Carburising flame, Oxidising flame, Al-MMC, BUE.
Thermal Stress Prediction within the Contact Surface during Creep Feed Deep Surface
Grinding
1*
Audhesh Narayan1* and Vinod Yadava2
Department of Mechanical Engineering, Motilal Nehru National Institute of Technology Allahabad -211004
1*
E-Mail: [email protected],2India, E-Mail:[email protected]
This paper presents the application of a hybrid approach comprising of Neural Network (NN) and Genetic
Algorithm (GA) for modeling and optimization of Creep Feed Deep Surface Grinding (CFDSG) process.
Finite Element Method (FEM) has been used to generate data set for NN model to predict the equivalent
thermal stress within the contact zone of the workpiece. Subsequently, NN model has been coupled with GA to
find optimum input-output parameters of CFDSG. The proposed hybrid approach is well capable to predict
thermal stresses in the workpiece quickly and also minimize it with reasonable accuracy during CFDSG
process.
Keywords: Creep Feed Deep Surface Grinding, Finite Element Method (FEM), Neural Network, Genetic
Algorithm
Prediction of Surface Roughness on Dry Turning Using Two Different Cutting Tool Nose
Radius
Uddipta Gautam1, Sanghamitra Das2* and D.K.Sarma3
Uddipta Gautam, Mechanical Engineering, Tezpur University-784028
2*
Sanghamitra Das, Mechanical Engineering, Tezpur University-784028
3
D.K.Sarma, Deptt. of Mechanical Engg., National Institute of Technology Meghalaya, Shillong-793003
E-Mail:[email protected], [email protected]
1
The surface quality of the machined parts is one of the most important product quality characteristics and one
of the most frequent customer requirements. This paper presents experimental results of an investigation of the
effect of the cutting tool nose radius in terms of surface finish. The other parameters considered were- cutting
speed, feed and depth of cut. The Design of Experiment was considered as two levels four parameters Full
Factorial design. The work piece material was considered as Mild Steel in form of a cylindrical bar whose
length was of about 240mm and diameter about 50mm. The cutting tool material used was HSS material with
different tool nose radii of 1mm and 0.65mm respectively. The results were analysed numerically and plotted
considering surface roughness as ordinate and other cutting parameters as abscissa. The results indicated that
feed rate has a significant influence on surface finish. Comparing the effect of surface finish of both the tools,
the cutting tool with 1mm nose radius produced better surface finish than that of 0.65mm.
Keywords: Dry Turning, Tool Nose Radius, Surface Roughness
Performance Analysis of Cylindrical Grinding Process with a Portable Diagnostic Tool
R. Vairamuthu1,M Brij Bhushan2, R. Srikanth1 and N. Ramesh Babu3*
1
Research Scholar, Department of Mechanical Engineering,
Indian Institute of Technology Madras, Chennai 600 036,
E-Mail:[email protected],[email protected]
2
Engineer, Micromatic Grinding Technologies Limited,
Bangalore 562 111, E-Mail:[email protected]
3*
Professor, Department of Mechanical Engineering,
Indian Institute of Technology Madras, Chennai 600 036, E-Mail:[email protected]
This paper presents an approach to develop a diagnostic tool that can monitor the power drawn by the spindle
motor using a power sensor and infeed of grinding wheel using a linear variable differential transformer
(LVDT) in cylindrical grinding machine. A combination of spindle power and wheel infeed measurement
enables the performance evaluation of grinding process. This evaluation suggests the possibility of optimizing
the grinding cycle in order to enhance the efficiency of grinding process. The effectiveness of the developed
in-process, portable diagnostic tool is demonstrated with a case study.
Keywords:Diagnostic system, Process monitoring, Power measurement, Optimization
Application of Artificial Neural Network for Modeling Surface Roughness in Centerless
Grinding Operation
Mondal1* S.C. and Mandal2 P.
Department of Mechanical Engineering, Indian Institute of Engineering Science and Technology, Shibpur,
Howrah 711103, India, E-Mail:[email protected]
2
Howrah 711103, India, E-Mail:[email protected]
1*
There is growing need among the manufacturers to model process performance in a centreless grinding process
using appropriate modelling techniques. This paper presents an application of artificial neural network (ANN)
for modeling surface roughness in centreless grinding process. The design of grinding factors is based on a full
factorial design of experiment. Centerless grinding operation is widely used in modern manufacturing industry
because of its high level of accuracy for micro-finishing of shaft, pin material compare to conventional
grinding operation. The experimental data is collected for machining a pin of C 40 steel material used in the
bottom block of crane-hook. The design factors (regulating wheel speed, depth of cut and coolant flow) are
selected based on experimental design methodology. Full factorial design method is applied for taking three
factors at three levels each and a total 33 or 27 number of experiments are done in all possible combination of
these parameters. The network model is trained by back propagation algorithm. Out of 27 data 20 experiments
used to train the network and for validation and the rest 7 data used for test. The learning rate, momentum coefficient and the number of neurons in the hidden layer are found by trial error method. Optimum architecture
has been found based on mean square error and convergence rate. The learning rate, momentum co-efficient
and the number of neurons in the hidden layers are found by trial and error method. In present work for
architecture 3-5-1 network with =0.02, and = 0.6, the mean square error for training is 0.000002433 and for
testing is 0.00000385 which is minimum. So it is found that optimum network is 3-5-1. The performance of
this particular trained neural network has been tested with the experimental data and found to be satisfactory.
Thus the proposed ANN model is efficiently used for predicting surface roughness in centerless grinding
operation.
Keyword: Centre-less Grinding, Surface roughness, Modelling, Design of experiment, Artificial Neural
Network
Desirability Analysis and Genetic Algorithm Approaches to Optimize Single and Multi
Response Characteristics in Machining Al-SiCp MMC
M.Chandrasekaran1* and Santosh Tamang2
12
Department of Mechanical Engineering, NERIST, Nirjuli, A.P.INDIA
E-Mail1*:[email protected], E-Mail2:[email protected]
Metal matrix composites (MMCs) having aluminum (Al) alloy in the matrix phase and silicon carbide (SiC)
particulates/particles in reinforcement phase have been found in common use for making components in
automotive and aircraft industries. Number of conventional (i.e., turning, milling, grinding, and drilling) and
non-conventional machining processes are employed for manufacturing MMC components. In this work, an
experimental investigation was carried out in turning Al-SiCp MMC (with less percentage of SiC particulates:
5% by weight) using poly crystalline diamond (PCD) insert. ‘Surface roughness (Ra)’ as job quality and
‘material removal rate (MRR)’ as job productivity are considered as two response parameters. A mathematical
predictive models based on response surface methodology (RSM) have been developed. Feed rate is found
most influencing parameter for obtaining Ra and MRR. The optimum process parameters are obtained for
optimizing single and multiple response characteristics employing two different approaches of optimization: (i)
statistical and mathematical approach based on desirability analysis (DA) and (ii) soft computing based genetic
algorithm (GA). The results are compared. Optimal Pareto fronts are obtained using GA provides suitable
combination of process parameters providing higher material removal rate at desired surface roughness.
Keywords: Turning, Metal matrix composites, Desirability analysis, Genetic algorithm.
An Experimental Investigation into the Applicability of Boric Acid as Solid Lubricant in
Turning AISI 4340 Steel
APS Gaur1 and Sanjay Agarwal2*
Bundelkhand University, Jhansi, U.P.284128, INDIA
2*
Bundelkhand Institute of Engineering & Technology, Jhansi, U.P.284128, INDIA,
1
The intense heat generation during the turning process is critical to the workpiece quality. Coolant and
lubrication therefore play decisive roles in turning. The conventional cutting fluids employed in machining
have certain limitations with regard to their use for ecological and economic reasons. Development of
lubricants that are eco friendly is acquiring importance. In this context, application of solid lubricants has
proved to be a feasible alternative to the conventional cutting fluids. Solid lubricant, if employed properly,
could control the machining zone temperature effectively by intensive removal of heat from the machining
zone. Therefore, the aim of present study is to investigate the effect of boric acid as solid lubricant in the zone
of machining. Experiments were carried out to investigate the role of solid lubricant such as boric acid on the
surface finish of the product in machining AISI 4340 steel by TiAlN coated tungsten carbide inserts of
different tool geometry under different cutting conditions. Results indicate that there is considerable reduction
in the cutting forces, average tool flank wear, and the surface roughness of the machined surface with boric
acid assisted machining compared to dry and wet machining. Chip thickness ratio is also evaluated to study the
lubricating action of selected solid lubricant during turning.
Combined Approach for Studying the Parametric Effects on Quality of Holes Using RSM
and PCA in Drilling of AISI-304 Stainless Steel
Suman Chatterjee1*, Arpan Kumar Mondal2 and SibaSankar Mahapatra3
1
Mechcanical Engineering Department,NIT, Rourkela 769008
2
Mechanical Engineering Department, IIT, Guwahati 781039
3
Mechanical Engineering Department, NIT, Rourkela 769008
The present investigation presents a mathematical model for prediction of burr height and circularity of AISI304 stainless steel hole using response surface methodology (RSM) and principal component analysis (PCA).
During drilling, one of the major problems arises regarding quality of holes is burr, due to which further
machining is required to achieve the required surface finish. Generally the response surface methodology is
used for modeling and analyzing manufacturing problems. As the traditional RSM unable to solve the multi
response problem, weighted principal component analysis (WPCA) is coupled with RSM method. PCA is
applied to estimate the weightage of the characteristics responses such that their relative importance can be
appropriately and objectively described. Weighted principal component analysis (WPCA) technique which
used to eradicate response correlation and convert the correlated responses to non-correlated quality indices
known as principal components (PC) and further this PC are aggregated to calculate the compound principal
component known as MPI (multi-response performance index). The study coupled RSM and WPCA to predict
the optimal parametric setting.The purpose of this study is to investigate the influence of control parameters,
such as spindle speed, feed rate, and drill bit diameter on burr height and surface roughness while drilling
AISI-304 stainless steel. The optimization results showed that the combination of high spindle speed, high feed
rate has maximum effect on the surface finish and hole quality (circularity and burr), but drill diameter has
average effect. As the optimal setup is present in experimental trail is present confirmation test was not done to
know the validity of the developed model. It has been found that the developed mathematical model for
prediction to be matching with the experimental results.
Keywords: Burr, Circularity, Drilling, PCA
Study & Optimization of Parameters for Optimum Cutting condition during Turning
Process using Response Surface Methodology
Shivraj Singh1, Harvinder Singh1, Harry Garg2*,
1
2
University College of Engineering, Punjabi University Patiala, Punjab India, 147002
Central Scientific Instruments Organisation(CSIR-CSIO), Chandigarh, India, 160030
In the present study effect of cutting parameters on surface finish are measured and are optimised. The
experiments are performed using Al6061 as work material and is machined by using insert CNMG 120408ENTM (H20TI). Response Surface Methodology (RSM) is used for designing the experiment. Cutting Speed,
Depth of cut and Feed are the selected input parameters for turning and surface roughness is output response
parameter. For the present investigation the input variables values varies from the 150-250 m/min for speed,
0.1-0.2 mm/rev for feed and 0.1-1.5 mm for depth of cut. Regression equations are generated from the RSM.
Their functional relationship & effect on different parameters is studied. ANOVA is applied to know which
input parameter has most significant affect on the surface roughness. It was noticed that as spindle speed
increases the surface roughness decreases and with increase in feed rate roughness value increases. With
increase in the depth of cut up to some extent roughness increase then it starts decreasing. Surface roughness
greatly influences the functional aspect and quality. Minimum surface roughness provides better lubrication
and minimum wear. Number of investigations are conducted to know the performance of the cutting tool and
work material
Keywords: Turning, Response Surface Methodology (RSM), ANOVA, Al6061
Optimisation of Process Parameters in Turning of Grey Cast Iron with Mixed Oxide
Ceramic Tool using Taguchi’s Approach
S.K. Rajbongshi1, A. Borah2* and P.K. Choudhury3
Assam Engineering College, Guwahati, 781013, E-Mail:[email protected]
2
*Assam Engineering College, Guwahati, 781013, E-Mail:[email protected]
3
Assam Engineering College, Guwahati, 781013, E-Mail:[email protected]
1
The mixed oxide ceramic tool plays an important role in machining of grey cast iron. In the present work, a
combined technique using Taguchi’ s Orthogonal Array and Analysis of Variance (ANOVA) is employed in
both dry and air-cooled turning operations to optimise the cutting parameters in machining grey cast iron with
mixed oxide ceramic tool. The responses viz., surface roughness, flank wear, cutting force and feed force are
considered to determine the parameters which are of more influential in nature at optimum condition. The
present work is based on an earlier work in which three parameters were chosen as process variables: Cutting
speed, Feed and depth of cut. The experimental plan is designed using Taguchi’ s L8 Orthogonal Array (OA) to
determine the effective parameters at optimum condition. Present study helps to select those parameters which
are of more influential and to obtain an optimal setting of the parameters. This analysis shows that air-cooled
turning is a better option as compared to dry turning in altering flank wear, cutting force, feed force whereas
dry turning is a better option as compared to air-cooled turning in altering surface roughness.
Keywords: Dry turning, Air-cooled turning, S/N ratio, ANOVA
An Experimental Study on the Burr Formation in Drilling of Aluminum Channels of
Rectangular Section
1,2
Ratnakar Das1* and Tarakeswar Barik 2
School of Mechanical Engineering, KIIT University, Bhubaneswar-751024, Odisha, India
E-Mail*1:[email protected],E-Mail2:[email protected],
Now-a-days precision manufacturing has gained it importance in all manufacturing industries. The best
product dimensions and the minimization of time and cost of production has become a measure of concern.
Drilling process takes care about 35% of all the machining processes and influences the acceptability of the
products as the drilling process is at the most final processing stage in the production line. The burr, which is a
plastically deformed material, generated during drilling is unnecessary output and often lowers the surface
quality, reduces the product life and acceptability of the product. Total elimination of burrs during drilling
process is a difficult task, however, with proper selection of process parameters it can be minimized. In the
present experimental study, analysis on burr formation has been carried out on the aluminum channel in
drilling process. The drill bit diameter and spindle speed are found to be most effecting parameters in burr
formation. Drilling of aluminum flat drilling has been done for comparison of results.
Keywords: Burr formation, Drill bit, Aluminum channel
Effect of Tool Wear on White Layer Thickness and Subsurface Hardness on Hard
Turned EN31 Steel
1
Gaurav Bartarya1* and S. K. Choudhury2
Harcourt Butler Technological Institute, Kanpur, India, 208002, E-Mail:[email protected]
2
Indian Institute of Technology Kanpur, India, 208016, E-Mail:[email protected]
The abrasive wear of the tool affects the service life performance of hard turned components. It results in the
higher cutting forces. It causes white layer and hardness variations in the subsurface region, thereby affecting
the surface integrity of the component. A white layer limits the fatigue life of hard turned part. The present
work analyzes the finish hard turning of AISI 52100 grade steel using uncoated Cubic Boron Nitride (CBN)
insert with predefined flank wear. The experiments were performed for various cutting speeds and tool flank
wear values. An analysis was undertaken to study the effect of cutting parameters on white layer thickness,
hardness profile across the section, and the surface finish produced. An attempt has been made to develop a
workable concept to produce the best possible surface integrity while machining with the worn tools, within a
selected range of cutting parameters.
Keywords: Finish hard turning, Flank wear, White layer, Subsurface Hardness
A Study on the Minimum Quantity Lubrication in Grinding of Titanium Alloy
(TI-6Al-4V)
1
Monith Biswojyothi, 2A.S.S. Balan, 3N. Arunachalam and 4*L.Vijayaraghavan
Manufacturing Engineering Section,
Department of Mechanical Engineering, IIT Madras, Chennai-36
*Email : [email protected]
Recent developments and chaos on climate change has led to researchers and scientists world over to rethink
and bring impactful changes to the current manufacturing processes. Current manufacturing trends require
large usage of cutting fluids which has led to adverse climatic changes and increased costs to the industries.
With the aim to reduce the consumption of cutting fluids, Minimum Quantity Lubrication (MQL) strategy has
been adopted by various machining and grinding applications. In this work, the grinding of Titanium alloy Ti6Al-4V with minimum quantity lubrication conditions were carried out. In order to maintain a good surface
integrity and to improve the grindability of Ti-6Al-4V experiments were conducted by varying different MQL
parameters. The MQL parameters such as coolant concentration, coolant flow rate and air pressure were varied
and its influence on the grinding forces, surface roughness, surface texture data were measured and analyzed.
The results showed a decreasing trend in grinding forces and surface roughness with increasing coolant
concentration, increasing air pressure and increasing coolant flow rate. This indicates that the suitability of
MQL for grinding of titanium alloy to use in various applications.
Keyword: Minimum Quantity Lubrication (MQL), Grinding forces, Surface roughness, surface texture
An Approach to Development of Involute Spline on Large Parts Using CNC Machining
A. Velayudham1*, Prasmit Kumar Nayak2 and A.M. Junaid Basha3
1*
CVRDE, Avadi, Chennai, 600054, [email protected]
2
3
This paper describes the approach followed in machining involute spline on a crank shaped large size
component using CNC machining centre. For spline milling shell type tool holder with throw away involute
formed coated carbide inserts were used. To verify the involute geometry of the splines machined by CNC
milling, on the similar size component involute spline form was generated on gear shaping machine with the
same spline data. Comparative results of profile, lead and pitch errors are presented for involute splines
obtained by spline milling and spline shaping processes. The accuracy of results is better for spline milling as
compared to spline shaping.
Keywords: Involute spline, CNC machining centre, Throw away carbide insert, Spline shaping.
Lecture Halls
Student Activity Centre (New Building)
Abstracts of Machine Tool Design
Papers
Effect of Sleeve Shrink-fit on Bearing Preload of a Machine Tool Spindle: Analysis
using Finite Element Method
Aslam Pasha Taj1 and Chandramouli S.R.2*
ACE Designers Limited, Peenya Industrial Area, Bangalore-560058
Email1:[email protected],E-Mail2*:[email protected]
Shrink-fit is a well understood method of assembling precision sleeves on high speed Spindle. However, it is
not well understood that how badly miscalculated interference value affects the performance of a spindle
assembly. Authors here have made an effort to understand the behaviour of various values of interference and
its effect on the practical performance as regards to machine tool spindle assembly application. A novel
method is proposed to calculate and arrive at suitable and optimal interference values for spindle bearing
assembly taking up the challenges as regards to mapping functional requirements and tolerances. In order to
disallow axial movement of the bearing in a machine tool application sleeves are shrink fitted. Effect of hoop
stress created causes the spindle to deform, very close to the sleeve. Local deformation of spindles directly
affects bearing preload. Using FEA technique, a procedure is developed to calculate and optimise the required
interference. A case study is presented to describe the entire process.
Keywords: Shrink fit, interference fit, bearing preload, FEM, parametric program, spindle
DIY CNC: A Review
Dhaval B. Patel1* and Aniruddh R. Kyada2
1
*Assistant Professor, Gandhinagar Institute of Technology, Gandhinagar – 382721
2
Assistant Professor, Silver Oak College of Engineering& Technology – Ahmedabad – 382481
The CNC machines are there from many years, but mostly they are unreachable to vast community specially
students. Another disadvantages with them is that they are bulky and expensive. Why can’ t we make a CNC
like printer? Why can’ t we make a CNC for small jobs with low capacity? There is lake of low cost CNC in
market which can teach and also work. All CNC are general in terms of controlling (you just have to control
three axis just that) but it produce more complexity when they came in existence. They produce different
output i.e. drilling, milling, turning etc. In this paper we are showing that how you can build up CNC using
open source hardware and software? What are the basic requirement for building a CNC and how to control
them?
Keywords: DIY CNC, CNC
Optimization of Cutting Tool Geometry by CAE Approach for Titanium Alloy
K. Pradeep Kumar Mouli1, Srinivasa Rao Nandam2, P. Vijay Kumar Raju3, G. Appala Raju4 and A.
Chandrakanth5
1
P.G. Student, SRKR Engineering College, Andhra University, Bhimavaram-534204
2
Scientist, Defence Metallurgical Research Laboratory, Hyderabad-500058
3
Professor, SRKR Engineering College, Andhra University, Bhimavaram-534204
4
Technical Officer, Defence Metallurgical Research Laboratory, Hyderabad-500058
5
Asst. Prof., MVSR Engineering College, Osmania University, Hyderabad-500058.
Titanium alloys are extensively used in aerospace, automobile, chemical and medical applications due to their
classical properties of high strength to weight ratio, specific strength at high temperatures, corrosion resistance,
creep and fatigue strength etc. Manufacture of precision components from titanium alloys is a challenging task
as the alloys comes under difficult to cut material due to the inherent qualities of low thermal conductivity, low
modulus of rigidity, work hardening, high chemical reactivity with tool, built-up edge formation etc. during
machining. The cutting tools exhibits forces on the work piece and similar forces are experienced by the
cutting tool while cutting the work material. Cutting tool geometries such as cutting angles and nose radius
play a vital role in machining of any work material (titanium alloys). The rake angles have major effects on
cutting forces and chip formation by giving adequate strength to the cutting tool. The tool nose radius has
effect on strength of the cutting edge and surface finish. The manufacturing engineers always quest for
optimized cutting tool geometry, but it is very difficult to carry out the experiments with various tool
geometries as it involves consumption of tools, material and time etc. Hence, to address the above issues, a
computer aided engineering (CAE) approach has been adopted in the recent days. Here, the cutting tool
geometry was optimized by design of experiments (DOE) techniques and a machining simulation and analysis
(Deform 3D) software by defining required material properties of titanium alloy (Ti-6Al-4V), tool geometry,
cutting parameters etc. The axial directional feed force (Fx), radial directional thrust force (Fy) and tangential
cutting force (Fz) were calculated for turning experiments through computer aided machining simulations.
These cutting forces were analyses in statistical (Minitab) software for percentage contribution of cutting tool
geometries such as back rake angle, side rake angle and nose radius and subsequently the optimized values
were evaluated. These achieved values are used to obtain the predicted cutting force values. The predicted
cutting forces were validated through experimental machining of Ti-6Al-4V cylindrical sample on precision
lathe machine by positioning optimized cutting tool geometry on a piezoelectric based precision cutting force
dynamometer of Kistler, Singapore. It is found that the experimental results which are obtained from the
experiments are almost near to the computer aided simulation experimental values. Therefore, the above CAE
approach can be employed before machining of advanced materials to get optimal values.
Keywords: Titanium Alloy, Cutting Force, Tool Geometry, CAE approach, DOE Techniques.
Experimental Modal Analysis (EMA) of a Spindle Bracket of a Miniaturized Machine
Tool (MMT)
Rajesh Babu, K.1 and Samuel, G. L.2
Department of Mechanical Engineering,
IIT Madras, Chennai – 600 036, India.
2
IIT Madras, Chennai – 600 036, India.
1
In many cases, modal tests are conducted on individual components of complex engineering structures where
interest is confined to deriving an undamped model of the structure. In the present study, we focus on
conducting modal test on a spindle bracket of a Miniaturized Machine Tool (MMT), a prototype of which is
available in our laboratory. The spindle bracket is a very vital component of a MMT as it acts as a bridge
between the machine’ s spindle assembly and its vertical slide/column. Developing an undamped model for the
spindle bracket with the aid of modal testing will enable us to predict the natural frequencies of the bracket so
that it allows us to visualize its impact on the natural frequency of an entire assembly of a machine tool, when
pressed into operation. An experiment was conducted on the specimen by an impulse hammer and three peak
values from the frequency response function (FRF) were taken into account to identify its vibration parameters
viz., natural frequency, damping ratio, and modal constants by the peak – picking method. Furthermore,
stiffness and damping matrices of a spindle bracket were also extracted from the experimental data.
Keywords: Experimental modal analysis, Frequency response function, Peak – picking method
Abstracts of Metal Forming
Papers
An Efficient Inverse Method for Determining the Material Parameters and Coefficient
of Friction in Warm Rolling Process
V. Yadav1, A.K. Singh2* and U.S. Dixit3
Department of Mechanical Engineering, Indian Institute of Technology Guwahati–781039
Email: [email protected],
2*
Department of Civil Engineering, Indian Institute of Technology Guwahati–781039
3
1
In this work, the material parameters for power law and coefficient of friction are obtained using inverse
analysis by measuring exit strip temperature and slip. The procedure makes use of finite element model for
deformation and an analytical method for the estimation of temperature. A heuristic optimization algorithm
is used for this purpose that minimizes the error between the measured and estimated flow stresses. The
method is verified by conducting some numerical experiments. Less than 1% error is observed.
Keywords: Flow stresses,Warm rolling,Finite element method, Inverse analysis
Design and Development of Single Point Incremental Sheet Forming Machine
Yogesh Kumar*1 and Santosh Kumar2
Mechanical Engineering Department, Indian Institute of Technology (BHU), Varanasi (UP), India, 221005
2
Mechanical Engineering Department, Indian Institute of Technology (BHU), Varanasi (UP), India, 221005
1
Single Point Incremental Sheet Forming (ISF) is one of the most advanced techniques in the domain of
flexible sheet forming process to produce complex products, which do not require any expensive and
dedicated forming tools (punch & die). The Laboratory setup of Incremental Forming Machine has been
developed. A Motion card has been used to control the 3 servo motors giving capability of individual 3 Axis
controlling. The forming trials are carried out based on simulation study of incremental forming process.
The strain distribution over the length of deformation has been computed.
Keywords: Incremental Sheet forming, Dieless forming, Modeling, Simulation etc.
Review of Rubber Based Sheet Hydro-Forming Processes
Abhishek Kumar1, Santosh Kumar2 and D. R. Yadav3
1
Defense Research and DevelopmentLaboratory, Hyderabad, 500058
E-mail:[email protected]
2
Indian Institute of Technology (BHU), Varanasi (UP), India, 221005
3
Defense Research and Development Laboratory, Hyderabad, 500058
Rubber based forming process is a versatile metal fabrication process used in commercial aerospace,
automotive and defense applications. It is well suited for prototyping and production of small quantities of
sheet metal parts. Rubber based forming employs a rubber pad contained in the rigid chamber or flexible
diaphragm as one tool half, requiring only one solid half to form a part to final shape. The solid tool half is
similar to the punch as in conventional process. The rubber exerts nearly equal pressure on all work piece
surfaces due to its incompressibility. The multi-directional nature of the force from the rubber pad produces
variable radius during forming and thus enhances uniform elongation of the work piece. The process
exploits the benefits of flexible rubber punch and produces the complex shaped sheet metal components
with minimal spring back and profile deviation. Parts with excellent surface finish can be formed with no
tool marks and severe variations in the metal thickness, as occurs in conventional forming processes, is
reduced considerably. Some of the very popular processes under Rubber-pad forming are Guerin process,
Marform deep drawing process, Verson Hydroforming process, SAAB rubber diaphragm process and
Maslennikov’ s process. The paper discusses in brief about these processes and presents literature review of
various developments occurred in this field.
Keywords: Rubber-pad, Forming, Hydroforming, Sheet metal
Feasibility Study of Thermal Autofrettage Process
S. M. Kamal1* and U.S. Dixit2
Department of Mechanical Engineering, Indian Institute of Technology Guwahati-781 039
2
1*
Autofrettage is a metal fabrication technique which applies to components subjected to very high pressure
such as gun barrels, rocket shells, high pressure piping, high pressure containers etc. The process is carried
out either by inducing an ultra-high hydraulic pressure in thick walled cylindrical pressure vessel, called
hydraulic autofrettage or by forcing an oversized mandrel through the bore of the cylinder, called swage
autofrettage. This causes permanent deformation of the inner layer of the cylinder. The outer layer remains
in the elastic state. Thus, compressive residual stresses are generated at the inner layer of the cylinder which
reduces the maximum stress involved in the cylinder when it is pressurized in the next loading stage. This
work presents a novel method for achieving autofrettage that involves creating temperature gradient in the
wall of the cylinder. The proposed process is analyzed theoretically. Preliminary experimental investigation
of the process is also carried out. The simulation results and preliminary experiments indicate an
encouraging trend for the feasibility of the proposed process.
Keywords: Autofrettage, Thick-walled cylinder, Thermal residual stresses, Elastic-plastic interface
Implementing the Genetic Algorithm with VLSI Approach for Optimization of Sheet
Metal Nesting
K. Ramesh1*and N. Baskar2
Department of Mechanical Engineering, M.I.E.T. Engineering College,
Tiruchirappalli,Tamil Nadu - 620 007, India
2
Department of Mechanical Engineeering, M.A.M. College of Engineering,
Tiruchirappalli, Tamil Nadu-621 105, India
*1
As Engineering becomes more advanced and the business in the industrial world becomes more
competitive, hence optimization technique becomes an essential part of an any industry or organization. The
objective of this paper is to minimize the material wastage by the optimum layout of two-dimensional work
piece within constraints imposed by stock size and material. This approach deals with how it can be
effectively utilized in the sheet metal industry to have the best arrangement of irregular shaped parts in the
sheet. This can be possible by using genetic algorithm (GA) approach which provides a best sequence of
parts with their orientation and also deals with how the parts can be effectively utilized in sheet metal. This
analysis mainly depends on the cutting process, size and shape of the sheet for different combination of
parts and subsequent operations required on the part. This heuristic based genetic algorithm generates
optimum layout considering factors such as minimum material wastage with their orientation by eliminating
human efforts.
Keywords: Genetic Algorithm, initial population, cross over, mutation, strip
Control of Ovality in Pipe Bending: A New Approach
A. V. Kale1*and H. T. Thorat2
1*
Department of Mechanical Engineering, YeshwantraoChavan College of Engineering, Hingna
road, Nagpur, Maharashtra, India, Pin. 441110,
2
National Institute of Technology, Srinagar, Uttarakhand, India, Pin 246174,
This paper formulates and analyses results of experimentation of pipe bending process on a new modified
pipe bending mechanism. Ovality or flattening of pipe in the bent portion is a major defect and contributes
to poor quality of the bend, deforms the cross section and reduces the strength of the bend to cause easy
buckling of the pipe. Several other defects in addition to this drawback of the bending process necessitated
corrective action and modification in the existing equipment to bend pipe with minimum defects. Hence,
this work targets at design, development, fabrication and use of equipment, which will produce pipe bends
with better quality without sacrificing simplicity of existing equipment. Analysis of experimental data is
presented here
Keywords: Tube/Pipe Bending, Rotary Compression Bending, Ovality.
Studies on Effect of Feed stock Temperature in Continuous Extrusion
Devendra Kumar Sinha1 and Santosh Kumar2*
Department of Mechanical Engineering, Indian Institute of Technology (B.H.U.), Varanasi-221005,
INDIA,
2*
Department of Mechanical Engineering, Indian Institute of Technology (B.H.U.), Varanasi-221005,
INDIA,
1
The temperature of the feedstock in continuous extrusion process plays a vital role in the deformation of
feedstock. Temperature of the feedstock has considerable effects on the process characteristics of
continuous extrusion process such as total load and torque required to extrude the feedstock through the die
orifice. In this paper, a numerical investigation is made to study the effect of temperature of the feedstock on
the process characteristics such as load distribution, torque distribution, effective stress distribution,
effective strain distribution, temperature distribution, damage distribution and velocity distribution using
FEM simulation tools. The investigation result suggest that if the temperature of feedstock lies in the warm
range, then total load and torque required to deform the feedstock is considerably reduced in continuous
extrusion process. A number of case studies have been taken to establish the process for Aluminum alloy.
Keywords:Continuous extrusion forming, Finite element method, Simulation, DEFORM-3D
Exploring Forging Load in Closed-Die Forging
D. Sheth1a, Santanu Das1b*, A. Chatterjee2 and A. Bhattacharya3
Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani- 741235
E-mail: [email protected], [email protected]
2
Central Mechanical Engineering Research Institute, Durgapur- 713209, West Bengal
3
Department of Mechanical Engineering, Thapar University, Patiala- 147004, Punjab
The load required in forging are a function of size, shape, frictional characteristics and deformation
resistance of a metal. Attempts were made by researchers for modeling the forging load for specific
applications taking into account various parametric effects on it. In the present paper, theoretical modeling
and modeling in LS-DYNA facilitating the FEM analysis are carried out to calculate forging load.
Theoretical estimation is done using the slab method that helps predict load for forging lead for a typical
axi-symmetric type of upsetting job having inclined surfaces. Results obtained from the theoretical estimates
are compared with the simulated model made using LS-DYNA software. Theoretical values show slightly
higher forging load estimates than experimentally observed ones of others; however, LS-DYNA simulation
shows close matching with the experimental values.
Keywords: Forging, closed die forging, forging load, FEM.
1
Influence of Adhesive on the Spring-Back of Adhesive Bonded Sheets
Avinash Kumar Yadav, Ram Nivas, Ravi Kumar and R. Ganesh Narayanan*
Department of Mechanical Engineering, IIT Guwahati, Assam, India 781039
*
Usage of adhesives in joining thin metal sheets of high strength increases its scope in automotive and
aerospace industries as it reduces weight and material cost. The current investigation is aimed at
investigating the spring-back of adhesive bonded sheets during V-bending by varying the adhesive
properties. The effect of hardener to resin ratio of adhesive, with and without shim, wire reinforcement, and
adhesive thickness, was determined. It has been demonstrated that the spring-back of base sheet can be
reduced to a larger extent with the help of adhesives. The influence of H/R ratio on spring-back is
considerable of about 8-20° reduction depending on the presence or absence of shim. But the other two
parameters, adhesive thickness and wire reinforcement, show almost insignificant effect, with wire
reinforcement the least.
Keywords:Spring-back, V-bending, Adhesive properties, Deformation
Spring-Back of Friction Stir Welded Sheets: Experimental and Prediction
SudhindraKatre, Siddhartha Karidi and R. Ganesh Narayanan*
Department of Mechanical Engineering,IIT Guwahati, Guwahati 781039, India,
*
The objectives of the present work are, (i) to investigate the influence of tool rotational speed and welding
speed on the spring-back of Friction Stir Welded (FSW) sheets, and (ii) to predict the same at different
welding conditions using finite element simulations. The base sheets used are Al5052H32 and Al6061T6 of
2.1 mm thickness. FSW sheets are fabricated at different tool rotational and translational (welding) speed.
Spring-back has been evaluated during V-bending and compared for analyses. Hill’ s 1990 yield criterion is
used in the finite element model for spring-back prediction. The spring-back of FSW sheets lie in between
that of Al6061T6 and Al5052H32 base sheets. Reduction in spring-back of FSW sheets is observed at
higher rotational speed and welding speed, which correlates with the changes in y/E ratio and n value of
weld zone. There exists a close agreement between experimental and predicted spring-back values.
Keywords:Spring-back, Friction Stir Welding, Prediction, Weld zone
Effect of Yield Strength, Pre-Strain and Curvature on Stiffness and Static Dent
Resistance of Formed Panel
G Manikandan*, Rahul K. Verma and Abhishek Raj
Research and Development, Tata Steel Limited, Jamshedpur 831001, India
*Corresponding author: Email: [email protected], Tel.: +91-657-2148964
Increased importance on weight reduction is driving automotive industries to reduce thickness of the steel
panels without compromising the vehicle safety and performance. High strength steels are looked at as a
candidate for automotive applications. To overcome the limitation of less formability in high strength steel,
steel makers introduced the bake hardening steel (BH) grades. This study compares the formability of high
strength automotive steel grades which are mainly used for body panels with that of bake hardening steel.
The influence of material properties, pre-strain ( o) and curvature(R) of product on its stiffness and static
dent resistance are studied experimentally. It was found that high material strength provides higher dent
resistance whereas high panel thickness and smaller curvature resulted in higher stiffness. Higher dent
resistance observed in bake hardened steel compared to high strength interstitial free steel is due to the
increase in strength by bake hardening process. The use of bake hardened steel in automotive applications
instead of high strength interstitial free steel represents a good opportunity for weight reduction, increased
stiffness and dent resistance.
Keywords: High strength steel, Bake Hardening, Formability, Dent resistance, Stiffness
Modelling of the Transformation of Coarse Grained Microstructure of α+β
β
TitaniumAlloys Along with FEM Simulation of Hot Forming Processes
M.K.Sarangi1*, S.K.Mandal2, B.K.Pradhan3, R.A.Vasin4, P.V.Chistyakov5,
O.I. Bylya6 and P.L.Blackwell7
1,2,3&4
Department of Mechanical Engineering, Institute of Technical Education and Research, Siksha ‘O’
Anusandhan University, Khandagiri Square, Bhubaneswar, Or, India., Pin-751030,
1
2
E-mail: [email protected],
3
4
5&6
Institute of Mechanics, Lomonosov Moscow State University, Michurinsky prosp-1, Moscow-119192,
Russia,
5
6
7
University of Strathclyde, 16 Richmond St, Glasgow G1 1XQ, UK,
7
It is well known that fine grained titanium alloys are characterized by very promising properties, but the
process of obtaining such materials is normally quite costly and time consuming. To reduce the cost of
manufacturing an attempt can be made to refine the initial coarse grained microstructure directly in the
process of hot working. Various experiments conducted by the authors as well as work carried out by other
researchers indicate that this is possible. The main complexity in the implementation of this idea into real
technological processes is related to the high non-uniformity of the strains, strain rates and temperatures in
the deformed work piece and the sensitivity of microstructural transformation to these parameters. To
approach this problem the capability of modeling the microstructure transformation along with the finite
element (FEM) simulation of the deformation process is required. In this work a simple constitutive model
coupled with the microstructure transformation is programmed into the FEM software, QForm, and used to
investigate the perspectives of hot forging of the coarse grained two-phase titanium alloy.
Keywords:Super plasticity, complex loading, + Ti alloys, constitutive modeling, FEM simulation
Investigation of Forming Behavior Prediction of Different Steel Grade Materials Using
Numerical Simulation
Sudhir Chakravarthy Katragadda1, Shaik Salkin2 and Perumalla Janaki Ramulu3*
Department of Mechanical Engineering, Holy Mary Institute of Technology, Hyderbad-501218
3*
Department of Mechanical Engineering, Vardhaman College of Engineering, Hyderbad-501218,
1&2
This study aims to investigate the forming behavior prediction of different steel grade materials using
numerical simulation. The simulation has been done using limiting dome height test (LDH) for different
automobile steel grade materials like HSLA, DP, TRIP, HSS, and DQ steel. In LDH test, the mechanical
properties are strain hardening exponent (n), yield strength ( ) including the plastic strain ratio in three
rolling directions (0º, 45º and 90º) are considered. The different strain paths are chosen from 25×200 to
200×200 i.e. from drawing to stretching side; in-total eight strain paths are considered for LDH test
simulation. The Hollomon’ s law for flow stress and Hill’ s 1948 yield criterion are used for all the simulation
by taking 1 mm mesh size for all strain paths. From the simulation results, the major strain and minor strain
developed at necking zone in all the strain paths are noted using thickness based necking criterion. Forming
limit curves are drawn using obtained major strain and minor strain. Thickness distribution compared for
better investigation of the formability among five steel grades. Results showed that better formability steel
showed better thickness distribution and vice versa.
Keywords: Advanced high strength steels; limiting dome height; forming limit curve; thickness distribution
Formability Studies on Aluminum Alloy Sheets through Deep Drawing Process
U. Pranavi1, P. Venkateshwar Reddy2 and Perumalla Janaki Ramulu3*
Department of Mechanical Engineering, Vardhaman College of Engineering, Hyderbad-501218
3*
12
In this paper, the effects of lubricating conditions and blank holding force on deep drawing process for
understanding the formability of AA 6061 aluminum alloy sheet of 2 mm thickness is studied. The
numerical simulations are performed for deep drawing of square cups at three different lubricating
conditions and blank holding forces. For numerical simulation PAM STAMP 2G a commercial FEM code
in which Hollomon’ s power law and Hills 1948 yield’ s criterion is used. Two different strain paths
(150x150 and 200x200) were simulated. Punch forces and dome heights are evaluated for all six conditions.
Failure initiation and propagation is also observed. From the overall results, it has been noted that by
increasing the lubricating conditions and blank holding forces, punch forces and dome height variations are
observed by which one can predict the formability for different strain paths.
Keywords:deep drawing; process parameters; blank holder force; friction coefficient
Experimental and Numerical Investigations on the Effect of Weld Zone on SpringBack in V-Bending of Tailor Welded Blanks of High Strength Steel
Vijay Gautam1* and D. Ravi Kumar2
1*
Department of Mechanical Engineering, DTU, Delhi-110042,
2
Department of Mechanical Engineering, IIT Delhi-110016,
Spring-back behavior in tailor welded blanks is very complex due to the differences in properties and
thickness and the effect of the weld zone. The presence of weld zone is one of the challenging issues in
numerical simulations for accurate prediction of spring-back in tailor welded blanks. Consideration of weld
zone properties in Finite Element simulations enhances the accuracy of the results although simulation time
increases. In this paper, experimental and numerical studies on the effect of presence of weld zone on
spring-back behavior of longitudinally welded tailor welded blanks in a V-bending operation are presented.
Tailor welded blanks, prepared by laser welding of high strength steel sheet specimens with three different
thickness combinations, have been used in the experimental studies. Two different punch profile radii of
10mm and 12.5mm have been used to characterize the spring-back. FE simulations have been performed
using ABAQUS with Hill'
s plasticity model and the results showed good agreement with experimental
results.
Keywords: Spring-back, Tailor welded blanks, Weld zone, V-bending.
Finite Element Analysis of Cross Rolling on AISI 304 Stainless Steel: Prediction
of Stress and Strain Fields
M. Rout1*, S.K. Pal1 and S.B. Singh2
Department of Mechanical Engineering, IIT Kharagpur, 721302,
1
Department of Mechanical Engineering, IIT Kharagpur, 721302
2
Department of Metallurgical and Materials Engineering, IIT Kharagpur, 721302
1*
Finite element analysis for cross rolling of AISI 304 austenitic stainless steel has been carried out by
rotating the plate by 90° in between the passes. To analyze stress and strain fields in the material for cross
rolling, a full 3D model of work-roll and plate has been developed using rigid-viscoplastic finite element
method. The stress and strain fields, considering von Mises yield criteria, are calculated by using
incremental Lagrangian method. In addition to these, the model also calculates the normal pressure and
strain rate distribution in the plate during cross rolling. The nature of the variations of stress and strain fields
in the plate, predicted by the model, is in good agreement with the previously published works for
unidirectional rolling.
Keywords: Effective stress, Effective strain, Cross rolling, DEFORM 3D
Analysis of Warm Deep Drawing for Ti-6Al-4V Alloy
1
Nitin Kotkunde1*, Sachin Rane1, Amit Kumar Gupta1 and Swadesh Kumar Singh2
Department of Mechanical Engineering, BITS-Pilani, Hyderabad Campus, Hyderabad, 500078,
2
Department of Mechanical Engineering, GRIET, Hyderabad, 500072,
An accuracy of finite element simulation for sheet metal forming is significantly dependent on the
trustworthiness of input properties and appropriate selection of material models. In this work, Hill 1948 and
CazacuBarlat anisotropic yield criteria have been implemented for Ti-6Al-4V alloy at 4000C. Material
constants required for the yield criteria have been determined using uniaxial tensile test. These yield criteria
have been implemented in commercial available DYNAFORM finite element software with LSDYNA
solver. In order to validate the finite element results, circular deep drawing experiment has been performed
at 4000C. Further, comparison of yield criteria based on thickness distribution and earing profile has shown
CazacuBarlat yield criterion is well suited for deep drawing of Ti-6Al-4V alloy.
Keywords: Ti-6Al-4V alloy, Yield Criteria, FEM, Thickness distribution, Earing Phenomena
Prediction of Forming Limit Curves for Extra Deep Drawn (EDD) Steel Using
Marciniak and Kuczynski (MK) Model
Sashank Srinivasan1*, Geetha Krishna A1, Shyam Krishna Shenoy A1,
Swadesh Kumar Singh2, Amit Kumar Gupta1
1
Dept. of Mechanical Engineering, BITS – Pilani, Hyderabad Campus, AP – India – 500078,
2
Dept. of Mechanical Engineering, GRIET, Hyderabad, AP – India – 500072,
*Corresponding author E-mail: [email protected]
Forming Limit Curves (FLCs) are an important tool for predicting the forming behavior of sheet metals.
Experimental measurements of FLCs are often time consuming and costly, and therefore, empirical
prediction methods carry significant practical importance. In this paper, an attempt is made to predict the
FLCs for Extra Deep Drawn (EDD) steel using Marciniak and Kuczynski (MK) model. In developing MK
model, three different yield criteria are used based on Hill (1948) and Barlat (1989) which are modeled
based on the true stress-true strain data obtained from the uniaxial tensile tests. The theoretical FLCs from
MK model have been validated with the experimental results obtained by the hemispherical dome tests with
specimens of different widths. The theoretical and experimental results are found to be in good agreement.
Keywords: Forming limit curves, Yield functions, EDD steel, MK model
Characterization of Mechanical Properties and Formability of Cryorolled Aluminium
Alloy Sheets
1
Fitsum Taye, 2Purnendu Das, 3D. Ravi Kumar and 4B. Ravi Sankar
1*Department of Mechanical Engineering, IIT Delhi, New Delhi,110016,
2Department of Mechanical Engineering, IIT Kharagpur, Kharagpur,721302,
3Department of Mechanical Engineering, IIT Delhi,New Delhi, 110016,
4Department of Metallurgical and Materials engineering, NIT, Tiruchirappalli,620015,
Al-Mg alloys are extensively used in aerospace and marine industries due to their high strength to weight
ratio and excellence corrosion resistance. Cryorolling is one of the important severe deformation processes
to produce sheets with high strength. But low formability of cryorolled sheets limits their use in automotive
industry. In the present work, formability of cryorolled AA5083 alloy sheets was characterized. Sheet
samples were cryorolled and cold rolled with 80% reduction in thickness and mechanical properties were
compared. Formability was determined in biaxialstretching mode through limiting dome height test. Partial
annealing in the range of 150° C to 300° C was done on cryorolled AA5083 alloy samples to improve
formability without significant loss of strength. Heat treatment in the range 200-250° C was found to be the
optimum temperature for achieving a good combination of strength and formability.
Keywords: Cold rolling, Cryorolling, Annealing, Formability.
Improvement in Accuracy of Failure Prediction in FE Simulations of Sheet Metal
Forming of Al Alloys
1
B Prajeesh, 2*D. Raja Satish and 3D. Ravi Kumar
1
BHEL Trichy, Tiruchirappalli,Tamilnadu,10016,
2*
Department of Mechanical Engineering, IIT Delhi,NewDelhi,110016
3
Department of Mechanical Engineering, IIT Delhi, New Delhi,110016,
In this work, the plane strain intercept on the forming limit diagram (FLD0) which is the major strain value
when the minor strain is zero, has been determined for some important aluminium alloys with a wide
variation in grade, heat treatment and thickness through stretch forming experiments. A new correlation
between formability parameters (thickness, strain hardening exponent and normal anisotropy) and plane
strain intercept in the forming limit diagram has been developed and it is used to generate forming limit
diagrams (FLDs) of these alloys in the post processor of FE software. FLDs generated using the developed
correlation have been found to be much closer to the experimental FLDs when compared to the FLDs
generated in the post processor based on the existing correlation. This has led to significant improvement in
accuracy of failure predictions (in terms of limiting dome height and failure strains) in the case of
aluminium alloys.
Keywords:Aluminium alloys, Forming Limit Diagram, Failure Prediction, FE Simulation.
Prediction of Formability of Bi-axial Pre-strained Dual Phase Steel Sheets Using Stress
Based Forming Limit Diagram
Shamik Basak1, Kaushik Bandyopadhyay 2, Sushanta Kumar Panda3*and Partha Saha4
Indian Institute of Technology Kharagpur, Kharagpur, 721302,
1
2
3*
4
Dual phase (DP) steel is of great interest for automotive part manufacturers due to its excellent
combinations of strength and formability. Complex components involving three-dimensional stampings are
usually fabricated through multistage sheet forming operations. The ability of a sheet metal to be deformed
into a specific desired shape by distributing strain over arbitrary tool surface depends on complex
interaction of material, process and design variables. The strain based forming limit diagram ( -FLD) is
often used as a measure of formability in the press shop due to convenience of measuring the limiting strain.
However, it was reported by previous researchers that the -FLD of sheet metal shifts after pre-strain due to
the initial forming operations. Hence, this present work proposes a mathematical framework for
constructing -FLD of different pre-strained sheet incorporating Barlat-89 yield criterion with different
hardening laws. The formability of biaxially pre-strained DP600 was evaluated experimentally in two
stages. The forming behaviour of pre-strained material was predicted by finite element model using the FLD, and prediction results matched very closely with experimental data. It was also observed that the FLD was robust and underwent insignificant changes due to the change in the pre-strain path.
Keywords: Stress based forming limit diagram, DP600, Pre-strain, LS-DYNA
Formability Studies on Aluminum Alloy Sheets through Deep Drawing Process
1, 2
U. Pranavi1, P. Venkateshwar Reddy2 andPerumallaJanaki Ramulu3*
3*
Department of Mechanical Engineering, Vardhaman College of Engineering,
Hyderbad-501218
In this paper, the effects of lubricating conditions and blank holding force on deep drawing process for
understanding the formability of AA 6061 aluminum alloy sheet of 2 mm thickness is studied. The
numerical simulations are performed for deep drawing of square cups at three different lubricating
conditions and blank holding forces. For numerical simulation PAM STAMP 2G a commercial FEM code
in which Hollomon’ s power law and Hills 1948 yield’ s criterion is used. Two different strain paths
(150x150 and 200x200) were simulated. Punch forces and dome heights are evaluated for all six conditions.
Failure initiation and propagation is also observed. From the overall results, it has been noted that by
increasing the lubricating conditions and blank holding forces, punch forces and dome height variations are
observed by which one can predict the formability for different strain paths.
Keywords:deep drawing; process parameters; blank holder force; friction coefficient
A Review on Micro-extruded Microstructure from Ultra-fine Grained and as Cast
Pintu Kumar1 and Sudhansu Sekhar Panda2
Department of Mechanical Engineering, IIT Patna, Patna, Bihar, 800013,
1
2
As per industrial requirement and application of micro part in micro-manufacturing process, grain size is an
important factor. Studying microstructure revels the size of grain, based on this different types of grains are
defined. Deformation behavior in micro extrusion process of coarse grain (CG) material is inconsistent
when scale changes from macro level to micro level known as size effect. Hence refinement of grain is done
through different approaches by severe plastic deformation (SPD). Such Ultra fine grain (UFG) material is
useful for micro extrusion process as its property are enhanced as compared to CG material obtained from
as cast. Equal channel angular pressing (ECAP) is one of the best techniques of SPD to produce UFG
material with shear deformation. Refinement of grain is done through number of passes using ECAP which
changes the size of grain up to nanometer level. Beyond certain number of passes grain size do not alter and
leads surface defects. As cast micro extruded product seems to be inhomogeneous and having wide
deviation of physical and mechanical property all along its axis. Whereas ECAP based micro extruded
product is homogenous and having uniform physical and mechanical property all along its axis. The
advantages of ECAP based micro extrusion is that grain size and direction of grain can be altered based on
requirements and type of application.
Keywords: Micro-extrusion, CG, UFG, Changed property
1, 2
On the Reduction of High Starting Load in Cold Drawing of Circular Tubes
G. Mathan1, G. Manikandan1*, Abhishek Raj1and Ashish P. Rajgure2
1
2
Tube Division, Tata Steel Limited, Jamshedpur 831001, India
High starting load during cold drawing process is an important factor affecting draw bench capacity
utilization. Finite element simulation was used to optimize die parameters to reduce the high starting load.
The shape of the pointed end was optimized to minimize high starting load. Experiments were conducted by
modifying the dies of pointers and the resulting drawing force was measured. It was observed that the
pointing operation creates out of roundness and due to that a high starting drawing force is required for
drawing operation.
Keywords: cold drawn tubes, finite element simulation. Folding pointers
Paper #AIMTDR-O0664(Oral presentation)
Effect of Process Parameters on the Mean Diameter of AA6082 Flow Formed Tubes an Experimental Investigation
1
M. Komaraiah1, M. Srinivasulu2* and C.S. Krishna Prasada Rao3
Sreenidhi Institute of Science and Technology, Ghatkesar, Hyderabad, Telangana
State, India- 501301,
2*
Govt. Polytechnic for Women (M), Badangpet, Department of Technical Education, Telangana State,
India-500058, Email: [email protected]
3
Bharat Dynamics limited, Kanchanbagh, Hyderabad, Telangana State, India-500058, Email:
[email protected]
Flow-forming is an advanced, chip less metal forming process employed for the production of thin walled
seamless tubes. Experiments were conducted to flow form AA6082 pre-forms on flow forming machine
with a single roller. The main flow-forming parameters selected for the present investigation are axial feed
of the roller, speed of the mandrel, and radius of the roller. The effects of these input parameters on the
mean diameter of flow formed tube have been critically analyzed by Taguchi method. It has been found that
the axial feed is the most significant process parameter influencing the mean diameter of flow formed tube
followed by radius of the roller. The tubes with desired nominal mean diameter of 43.00 mm are produced
by flow forming process when the process parameters were set at their optimum values.
Keywords: Flow-forming, AA6082 alloy, Mean diameter, Taguchi method
Application of a New Friction Model in Circular Cup Drawing
1*
Ravindra K Saxena and 2Anuj Sharma
SantLongowal Institute of Engineering and Technology, Sangrur-148106 PB
1*
In deep drawing operation, friction plays an important role. Friction also influences the stresses and strains
in the work-piece material and, hence, the quality of the product. In sheet metal forming simulations, the
Coulomb’ friction model is often used. The friction coefficient is dependent on contact pressure and/or
deformation of the sheet material. When two surfaces come in contact, the surface texture of a material
changes due to the combination of normal loading and stretching. A recently proposed friction model based
on the surface changes on the micro-scale is incorporated into an in-house FE deep drawing code to find its
effect. The results show a realistic distribution of the coefficient of friction depending on the local process
conditions.
Keywords: Friction modeling, flattening mechanisms, real contact area, ploughing, adhesion.
Abstract of Casting
Automated Vision Inspection System for a Plastic Injection Mould Component
R. Deepa1*, S. Usha2 and P. V. Shashi Kumar3
Central Manufacturing Technology Institute, Tumkur Road, Bangalore-560022
1*
E-mail: [email protected], 2 E-mail: [email protected], 3 E-mail: [email protected]
This paper presents an automated vision based defect inspection and sorting system for a plastic injection
mould component called a Retractor Retaining Bush, which is an automotive safety critical component. The
system identifies defects which usually occur in a plastic injection mould component. Various types of
sensors and actuators were interfaced with the vision hardware and the part handling mechanism, to
complete the total automated vision based inspection system.
Keywords: Vision Inspection, Plastic inspection, Defect identification
Computer Aided Runner and Gating System Design from Die-Casting Part Model
Ranjit Singh1 and Jatinder Madan2*
Department of Mechanical Engineering, Sri Guru Granth Sahib World University, Fatehgarh Sahib 140406 Punjab, India
2*
Department of Mechanical Engineering, Chandigarh College of Engineering and Technology (Degree
Wing), Chandigarh -160019, India
1
Runner and gating system design is one of the important activities of die-casting die design. In normal
practice, a die-casting expert makes use of the expertise gained taking care of many factors, such as material
properties, industry best practices and physics of the process to determine the runner and gating design
parameters. These parameters are then optimized by conducting process flow simulations on a computer and
dry runs on a die-casting machine, which usually requires a number of iterations. These iterative activities
increase the manufacturing lead time and makes the die-casting die-design a tedious process. A system
which could reduce the iterations and make the design process more efficient is highly desirable. This paper
presents a computer-aided system for runner and gating system design for a die-casting die. The system first
generates runner and gating system parameters based on part, material and machine information. The system
makes use of a runner and gating system feature library that has been built in this research. Lastly, the user
decides the placement of the runner and gating system, along the parting line of the die-cast part. The results
obtained from the system for some industrial die-casting parts are as per the practices being followed in the
industry.
Keywords: Die-Casting, Die-design, Gate, Runner, Gating System Design
Investigation of Mechanical and Tribological Properties of A356/Al2O3/graphite by Stir
with Squeeze Casting Method
G.Nagesh1, Sukesha,V.2, Rajeev Ranjan3 and K. Sekar4
Mechanical Engineering Department, NIT Calicut, 673601,
1*
E-mail: [email protected], 2 E-mail: [email protected],3 E-mail: [email protected]
4
In the present work Stir with Squeeze casting process was introduced. And the commercial A356
Aluminium alloy reinforced with nanoAl2O3 (1wt%)and micro graphite(0.5, 1and 1.5wt%)particles were
used for the present study.A356 alloy belongs to a group of hypoeutectic Al-Si alloys and has wide
applications in automotive, marine and the mechanical properties of cast Al-Si alloy parts largely depend on
grain size and its morphology. Graphite, Al2O3 based A356 composite is a refractory compound that
exhibits outstanding features such as high melting point, high hardness and high wear resistance due to the
T6 heat treatment. After T6 heat treatment, the microstructures of (graphite+Al2O3) undergo a remarkable
change, leading to the improvement of tribological and mechanical properties of composites and the
mechanical properties of (1.5%graphite+ 1%AAl2O3) are superior to those of the composites reinforced with
0.5%Graphite or 1%Al2O3 particles. And the wear rate of the composite decreased dramatically and the
tensile strength was decreased with weight percent of graphite. From SEM and EDS analysis of bright field
images, the ceramic phase in A356/Al2O3/graphite hybrid composites were found to be homogenized and
uniformly distributed. And weight fraction, the weight loss, wear rate and friction coefficient of the
composites were the most important factors that affected the mechanical as well as tribological properties.
Keywords:Hybrid composite, Weight loss, Tribological properties
Mathematical Modeling of Solidification in a Curved Strand during Continuous
Casting of Steel
Ambrish Maurya1* and Pradeep Kumar Jha2
*MIED, Indian Institute of Technology, Roorkee, 247667,
2
MIED, Indian Institute of Technology, Roorkee, 247667,
1
A two dimensional fluid flow, heat transfer and solidification model has been developed for a curved shape
continuous steel slab caster. The strand has been divided in various sections depending upon cooling
conditions in the mold and secondary cooling zone. The model was validated against the experimental
results for solid shell thickness in the mold as reported by Hakaruet al. (1984) CFD software Ansys Fluent
has been used for solving the differential equations to predict the temperature distribution, solid shell
thickness by finding the liquid fraction of steel within the domain. Process parameters, casting speed and
cooling rate has been varied to analyze their effects on metallurgical length and solid shell thickness at the
mold exit.
Keywords: Solidification, CFD, Mathematical Modeling, Metallurgical Length
A Numerical Study of Mould Filling in Micro-casting
Sateesh Kumar Yadav1, Rajesh Kumar Shukla2 and Arvind Kumar3*
Dept. of Mechanical Engineering, Indian Institute of Technology Kanpur,
Kanpur, India, 208016,
2
Dept. of Mechanical Engineering, Indian Institute of Technology Kanpur,
3
*Dept. of Mechanical Engineering, Indian Institute of Technology Kanpur,
1
Micro-casting facilitates the fabrication of small structures in the micrometer range or of bigger parts
carrying microstructures with high aspect ratio by means of solidifying molten metal in the
microstructuredmould. Micro-casting can manufacture very complex structures and is scalable and
economically efficient for mass production. In this paper, a numerical study of the mould filling in a microcasting process is presented. The micro-casting mould cavity contains micro-sized channels. The free
surface tracking method − Volume of Fluid (VOF)-based algorithm is used for predicting the free surface
flows and tracking the metal–air interface during the filling process. The model is demonstrated for the case
of filling of pure metal (aluminium) in the mould cavity, and the resulting evolution of the position of
molten liquid interface in the micro-casting part is presented. The level of molten metal in the micro channel
fluctuates because of the variation of the pressure. The capillary action play an important role in filling
process of the thin micro channel. It is observed that the filling in the micro channel is non-uniform and at
the end the micro channel gets completely filled.
Keywords: Micro-casting, Mould filling, Volume of fluid (VOF), Capillary action.
Experimental Investigations on the Microstructure of Aluminium 6063 with Copper
and Gun Metal
Tony Thomas.A1*, MuthuKrishnan.A2 and SreNandha Guhan K.S3
Mechatronics Engineering, Kongu Engineering College, Perundurai, Tamilnadu,638 052,
2
3
1*
A composite is a material that consists of at least two chemically and physically distinct phases suitably
distributed to provide properties not obtainable with either of the individual phases. Aluminium alloys,
aluminium nickel alloys, magnesium, steel, etc. has been used in recent times in aerospace and automotive
industries because of their high temperature resistance and superior strength to weight ratio. The objective
of the investigation is to fabricate a composite material which is to be used as an alloy wheels in automobile
vehicles. The MMC includes three metals which includealuminium 6063, copper and gun metal. Aluminium
is chosen because of its superior strength to weight ratio. Copper is chosen because of its ability to dissipate
heat quickly. Gun metal for its ability to with stand stresses.The fabrication of composite material is done
with the help of stir casting induction furnace.SEM (Scanning Electron Microscope) analysis has been done,
in order to show the dispersion of the copper and gun metal with the aluminium. By changing in weight
percentage of copper, gunmetal with Aluminium the differentmicrostructures are observed.
Keywords: Stir Casting, Aluminium Matrix Composites, Copper, Gun Metal, SEM
Computer-Aided System for Multi-Cavity Die-Casting Die-Design
V. Kumar1, 2*and J. Madan3
1
Sant Longowal Institute of Engineering and Technology, Longowal, Punjab-148106
2*
Anand International College of Engineering, Jaipur, Rajasthan-302021,
3
Chandigarh College of Engineering and Technology (Degree Wing), Sector 26, Chandigarh-160019,
Die-design for the die-casting process is a time consuming and complex activity that requires domain
knowledge and vast experience of the die-designer besides information about manufacturing resources, part
geometry, delivery time and cost preferences, etc. Complexity of the die-design activity further increases in
case of a multi-cavity die. Currently available die-design systems lack in the level of automation and do not
explicitly address multi-cavity die-design. In the present research work an attempt has been made to develop
a computer-aided system, which facilitates design of a multi-cavity die-casting die taking part product
model as input. Objective of the proposed system is to automate the process of cavity design, cavity layout
design, die-base design, core-cavity and side-core design, gating system design for a multi-cavity diecasting die. The proposed system, which we named Multi-cavity Die Designer, works as an add-on
application to an existing CAD software namely SolidWorks. The proposed system is divided into five
modules, namely Data Initialization, Cavity Design, Cavity Layout Design, Core-cavity& Side-core Design,
and Gating System Design. Use of commercial software like SolidWorksas a platform both for part design
and generation of die-design eliminates loss of data which makes the proposed system quite useful in the
industrial scenario. To demonstrate the capabilities of Multi-cavity Die Designer, it was tried for a number
of die-casting parts and the results for one industrial case study part are presented. Proposed system is a step
forward to design-manufacturing integration for die-casting process.
Keywords: Die-casting, Die-design, Multi-cavity, Core-cavity design.
Abstracts of Welding/Joining
Prediction of Weld Induced Angular Distortion of Single Sided and Double Sided Fillet
Joint by SAW Process
Arpan Kumar Mondal1*, Pankaj Biswas2, Swarup Bag3and Manas M Mohapatra4
Department of Mechanical Engineering, Indian Institute of Technology Guwahati, India-781039,
2
3
4
Department of Mechanical & Industrial Engineering, Indian Institute of Technology Roorkee, India247667, E-mail: [email protected]
1*
In this present work a numerical elasto-plastic thermo-mechanical model has been developed to predict the
weld induced angular distortion of single sided and double sided fillet joint by SAW process. The welding
was carried out by using recyclable flux-filled backing strip in single pass. The angular deformations for
both the cases have been measured experimentally. It has been found that the maximum magnitude of
angular deformation is lower in case of double sided fillet joint. A detail comparative study of the angular
deformation between single and double sided fillet joint has been presented in this study. It has been
observed that the developed elasto-plastic thermo-mechanical model is well comparable with experimental
results.
Keywords: Submerged arc welding, Elasto-plastic, Thermo-mechanical model, Single and double sided
fillet weld joint, Single pass, Angular deformation.
Optimization of Process Parameters in Submerged Arc Welding Using MultiObjectives Taguchi Method
A. Saha1 and S. C. Mondal2*
Department of Production Engineering, Haldia Institute of Technology, Haldia
West Bengal 721657, INDIA
2*
Department of Mechanical Engineering, Indian Institute of Engineering Science and Technology, Shibpur
Howrah 711103, INDIA
1
Submerged Arc Welding (SAW) is one of the oldest automatic welding processes to provide high quality of
weld. The quality of weld in SAW is mainly influenced by independent variables such as welding current,
arc voltage, welding speed and electrode stick out. The prediction of process parameters involved in
submerged arc welding is very complex process. Researchers attempted to predict the process parameters of
submerged arc welding to get smooth quality of weld. This paper presents an alternative method to optimize
process parameters of submerged arc welding (SAW) of IS: 2062, Gr B mild steel with multi-response
characteristics using Taguchi’ s robust design approach. Experimentation was planned as per Taguchi’ s L8
orthogonal array. In this paper, experiments have been conducted using welding current, arc voltage,
welding speed and electrode stick out as input process parameters for evaluating multiple responses namely
weld bead width and bead hardness. The optimum values were analyzed by means of multi objective
Taguchi’ s method for the determination of total normalized quality loss (TNQL) and multi response signal
to noise ratio (MRSN). The optimum parameters for smaller bead width and higher bead hardness are weld
current at low level (12.186 A), arc voltage at low level (12.51 V), welding speed at low level (12.25
mm/min) and electrode stick out at low level (12.29 mm). Finally, confirmation experiment was carried out
to check the accuracy of the optimized results
Keywords:Multi objective Taguchi method, Multi response signal to noise ratio, Submerged arc welding
Characterization and Optimization of Nd: YAG Laser Weld Joints of Dissimilar
Metals
A. P. Tadamalle1, Y. P. Reddy 2, E. Ramjee3 and K. V. Reddy 4
Department of Mechanical Engineering, Sinhgad College of Engineering, Vadgaon (Bk), Pune, India411041,
1
2
3&4
Department of Mechanical Engineering, Jawaharlal Nehru Technological University, Kukatpally,
Hyderabad-500085,
3E
-mail: [email protected],
4
1&2
The welding of dissimilar metals is challenging because of differences in physical, chemical and thermomechanical properties. This paper aims to investigate the influence of process parameters on strength,
microstructure and chemical composition of weld joints made of 304L stainless steel and galvanized iron
sheets. An empirical relationship in terms of laser power, welding speed and pulse duration has been
proposed for optimizing the weld strength using Taguchi and Response Surface Methodology. The set of
experiments are conducted as per the Taguchi’ s orthogonal array design matrix. The X-ray Difractometer
and Scanning Electron Microscope employed to characterize the weld joint. The PANalyticalX’ Pert High
score software is used to analyze phase contents. It is observed that laser power has more effect than pulse
duration on weld strength. The optimized strength predicted from dissimilar metal weld joints by using
experimental and analytical methods are close agreement with each other. The analysis of weld samples
depicts the formation of vanadium and manganese nitride precipitate at the grain boundaries.
Keywords:Nd: YAG Laser, XRD, SEM, Butt Welding, Dissimilar Metals, Optimization.
Effect of Shoulder Diameter and Plunging Depth on Mechanical Properties and
Thermal History of Friction Stir Welded Magnesium Alloy
Prakash Kumar Sahu1*and Sukhomay Pal2
Mechanical Engineering Department, IIT Guwahati-781039, India
1*
2
This paper is aimed to identify the effect of shoulder diameter and plunging depth on mechanical properties
and thermal history of the friction stir welded AM20 magnesium alloy. The results show that friction stir
welding (FSW) can be utilized for joining AM20 and gives better mechanical properties, namely ultimate
tensile strength, bending angle, and micro-hardness. The maximum tensile strength of the welded joint was
65%, to the base metal when the shoulder diameter was 24 mm. When shoulder diameter decreases the
contract surface area with the work piece also decreases which causes less frictional heat generation and as a
result joint strength decreases. The bending performance of the welds was found to be satisfactory. The
maximum bending angle of the welded joint is 450 whereas base metal bending angle is 900. The hardness
test was also done and it was found that the hardness of the upper zone is comparatively higher than the
middle and bottom zone, irrespective of the process parameters setting. It is also found that the hardness is
higher in the weld nugget zone compare to the heat affected zone and base metal. The maximum hardness at
the weld nugget zone was 59.57 HV and the base material hardness was 46 HV. So it is found that the
hardness increases up to 29.5 %. It was also found that less plunging depth give better tensile properties
compare to higher plunging depth because at higher plunging depth local thinning occurs at the welded
region. From the thermal history it was found that the maximum temperature occurred at higher shoulder
diameter and it was around 4650C, at1mm away from the welding line.
Keywords: Friction stir welding, Magnesium alloys, Mechanical properties, Thermal history
1*&2
Monitoring of Friction Stir Welding Process through Signals Acquired During the
Welding
Bipul Das1, Sukhomay Pal2 and Swarup Bag3*
Indian Institute of Technology Guwahati, 781039,
2
3*
1
Friction stir welding (FSW) patented in the year 1991, has not yet reached its full potential. Because it is a
new process and physical models are lacking in the field of FSW which makes it difficult to assure the weld
quality. The difficulty arises from the lack of data and monitoring processes regarding the influencing
factors that govern the welding process. In the current work, a converted milling machine developed for
friction stir welding is used to perform welding operations. Welding is carried out on 6 mm thick AA1100
series Aluminium alloy plates in butt joint configuration. Tool rotational speed and welding speed are the
two process parameters considered for the experiments varied in three levels as 815, 1100, 1500 rev/min and
63, 98, 132 mm/min respectively. Current and voltage signals for spindle motor and feed motor are acquired
along with the signal of rotational speed of the spindle. All the signals are acquired at 10 kHz sampling rate
using a high speed data acquisition system using MATLAB®. Ultimate tensile strength and yield strength of
the welds are measured and these are tried to correlate with the root mean square values of the signals
obtained during welding along with the process parameters.
Keywords: FSW, monitoring, signals, regression
Effect of Preheating on Mechanical Properties of Hybrid Friction Stir Welded
Dissimilar Joint
Deepak Kumar Yaduwanshi1, Sukhomay Pal2 and Swarup Bag3*
1,2&3*
Department of Mechanical Engineering, Indian Institute of Technology Guwahati,
Guwahati 781039, Assam, India
1
2
3*
Hybrid friction stir welding is an innovative solid-state joining technology which has great potential to
produce effective and defect free joint of dissimilar materials irrespective of high chemical affinity and
completely different physical and mechanical properties like aluminum and copper. Although, these factors
contribute to the asymmetry in both heat generation and material flow, these drawbacks may be overcome
by introducing additional local heating to preheat the copper side up to 200 and the optimum location of
the tool to provide adequate metal flow around the tool. Preheating prevents the formation of a large amount
of brittle aluminum-copper inter-metallic compounds. Among the possible preheating source, plasma arc
provides unique combination of high arc stability, concentrated energy density and low equipment cost.
Hence plasma assisted hybrid friction stir welding (P-FSW) of pure copper and AA1100 are investigated.
The mechanical properties of welded joint indicate that P-FSW of pure copper and AA1100 improves the
welding efficiency and weld jointquality.
Keywords:Hybrid friction stir welding, preheating, intermetallic compounds, mechanical properties
A Study on Tooling and Its Effect on Heat Generation and Mechanical Properties of
Welded Joints in Friction Stir Welding
Sujoy Tikader1†*, Pankaj Biswas2 and Asit Baran Puri3
Mechanical Engineering Department, IIT Guwahati, India-713209,
2
Mechanical Engineering Department, IIT Guwahati, India-781039,
3
Mechanical Engineering Department, NIT Durgapur, India-713209,
1*
Friction stir welding (FSW) has been the most attracting solid state welding process as it provides better
mechanical and metallurgical properties of the weld. Non-weldablealluminium alloys like 5XXX, 7XXX
series can be welded by this process without any difficulty. The butt welding is done using two thin plates
(200mm × 100mm × 6mm) of similar metals, i.e, alluminium alloys of grade AA1100. The tool material
was made of stainless steel (SS-310 tool steel). In the present study, the traverse speed of the tool was kept
constant while four different types of tool geometry, two different rotational speed of the tool alongwith two
different plunging forces were used. Thus, a set of eight experiments were conducted and mechanical
properties like micro-hardness and tensile strength of the welded specimens have been studied for different
process parameters settings. Also, a mathematical model is developed to estimate the generated heat in the
welding zone. It was noticed that friction is the major contributor for the heat generation. It was observed
that the tool rotational speed and traverse speed have varying effects on tensile strength and hardness of
FSWed joints. An attempt is also made to validate the theoretical model of the heat generation in the FSW
process.
Keywords: Friction stir welding, Stirring effect, TMAZ
Parametric Studies and Finite Element Analysis of Welded Steel in Resistance Spot
Welding Process
Kishore, N.1*, Sreenu, S.2, Ramachandran N.3 and Allesu, K.4
1*
NatinalInstitute of Technology Calicut, 673601,
2
NatinalInstitute of Technology Calicut, 673601,
3
National Institute of Technology Calicut, 673601,
4
National Institute of Technology Calicut, 673601,
Resistance Spot Welding (RSW) is a widely used joining process for fabricating sheet assemblies in the
automotive, marine and aerospace industries. Modern vehicles contain 2000-5000 spot welded points. The
main requirements of these automobile parts are corrosion resistance of chassis, the high strength values of
sheets used, the sti ness of welded joints when exposed to an external force and the ability to absorb
impacts, along with low cost and comfort. In RSW, electrodes travel on a predetermined path and make
contact with the sheets at selected weld points to apply force. Electric current is then turned on and flows
through the sheets clamped between the electrodes. Due to the contact resistance to current flow, the
temperature rises from resistance heating. When the temperature reaches the desired fusing temperature, a
molten nugget is formed, the current is shut off after a designated time to allow the nugget to cool down and
solidification of the weld spot occurs under pressure. It is proposed to study the effect of various parameters
on nugget dimensions and strength of the weld joint in RSW and concentrating on different material and
thicknesses to get good weld joint at low cost and compared with analytical part done in Ansys.
Keywords: Weld nugget, Tensile strength, Temperature distribution.
Estimation of Weld Pool Geometry and Cooling Rate in Laser Welding
1
Tadamalle A. P1*,Reddy Y. P1, Ramjee E2 and Reddy K. V2
Department of Mechanical Engineering, Sinhgad College of Engineering, Vadgaon (Bk) Pune, India411041,
2
Department of Mechanical Engineering, Jawaharlal Nehru Technological University, Kukatpally,
Hyderabad-500085,
The laser processing of materials has immense importance in design, development and fabrication of micro
products in multidisciplinary fields. The real time tracking and inspection of weld joints can be done by
using wide range of sensors available to monitor weld quality. This paper aims to predict weld bead
geometry from the images captured by high speed camera without filters during laser welding of dissimilar
metals. The high speed Y4 camera having image grabbing capacity of 2000 fps is used to record the welding
process of two different thick materials. A graphical user interface is developed to compute the weld pool
area and images are processed by using MATLab based image processing module. The effect of process
parameters on heat affected zone hardness has been analyzed. The images captured by the high speed
camera and analytical methods are successfully used to predict weld pool geometry and cooling rates. The
cooling rate and weld bead geometry obtained from experimental and analytical methods are compared and
found in close agreement with each other.
Key words: Weld pool geometry, Laser welding, Image processing and Micro hardness
Coupled Electromagnetic Structural Simulation of Magnetic Pulse Welding
Angshuman Kapil1* and Abhay Sharma2
1*
Indian Institute of Technology, Hyderabad, 502205,
2
Indian Institute of Technology, Hyderabad, 502205,
The present study deals with the Coupled Magnetic-Structural analysis of Magnetic pulse welding process
applied on a tubular workpiece. The study investigates the various criteria required for a successful weld
between the mating members through a Finite element model developed using COMSOL Multiphysics. The
transient electromagnetic field phenomenon is coupled sequentially with mechanical phenomenon. The
coupling between the magnetic field and the electrical circuit is formulated in the electromagnetic part of the
model, whereas in the structural part, the impact velocities, the effective plastic strain induced in the
workpiece and the direction and magnitude of the shear stress at the impact zone are found from the
numerical simulations. A viscoplastic material model with rate dependent material properties is considered
in the structural part. The effect of varying process parameters: input voltage and air gap between the two
mating members on weld quality are computed through numerical simulations. Based on the results of the
numerical simulations an optimal weldability window is suggested.
Keywords: Magnetic pulse welding, Coupled Magnetic-Structural analysis, Finite element model,
Weldability window
Investigation of Recycled Slag in Submerged Arc Welding of Pressure Vessels
1
S.B. Chandgude1 and S. S. Asabe2*
K.K.W.I.E.E.R, Nashik, Maharastra, India, 422001,
2*
U.C.O.E.R. Pune, Maharastra,India.413304,
Submerged arc welding is widely used for fabrication of pressure vessels in the industries. Flux is a major
content in such welding process and it produces slag. Storing and disposal of this slag is a major problem
encountered in the industries. In this study recycling of the slag has been carried out for one of the industry
with new combinations of wire and flux during the submerged arc welding of pressure vessels. Results of
chemical and mechanical analysis have been presented and compared with AWS and National Accreditation
Board of Laboratories standards. The economic aspects of recycling are also discussed in this paper.
Keywords: Slag, weld, recycling, flux Metal
Effect of Process Parameters on Tensile Properties of Friction Stir Welded Joints
Biswajit Parida1 and Sukhomay Pal2
Department of Mechanical Engineering, IIT Guwahati, 781039, India
2
Department of Mechanical Engineering, IIT Guwahati, 781039, India
1
Friction stir welding is a solid state welding process. In this process, the materials are joined due to the
frictional heat generated by a rotating non–consumable tool, consisting of a pin and shoulder, without
melting. The present work is on the study of effect of different process parameters on tensile properties of
welded joints. 1xxx series aluminium alloy has been used as the base material to prepare butt joint
configurations. The parameters considered are tool rotational speed (RPM), welding speed (WS) and tool
geometry (TG). The welding was carried out in a vertical milling machine with a special type of fixture.It
was found that joints with 1100 RPM showed highest ultimate tensile strength (UTS). The UTS value
increased from 600 to 1100 RPM and then decreased. Among the four type of tool geometries used in the
present work threaded tool exhibited highest strength and also the ductility. Tapered cylindrical tools
produced the weakest joint. The joint strength showed an increasing trend with respect to WS up to certain
value and then decreased due to improper material mixing at higher welding speed. This may be due to
insufficient heat generation.
Key-words: Friction stir welding, tool rotational speed, welding speed, tool geometry, ultimate tensile
strength, % elongation
CAFE Modeling to Predict the Grain Size during Friction Stir Welding of Aluminium
Grades
1,3
Sharad Valvi1, Sumitesh Das2 and R. Ganesh Narayanan3
Department of Mechanical Engineering, IIT Guwahati, Guwahati 781 039, India
2
Research & Development Division, Tata Steel, Jamshedpur 831 001, India
Friction stir welding (FSW) is an important and recently developed joining technology that produces a solid
state weld, which is characterized by non-melting of the work material. In the present work, the temperature,
strain-rate and grain size distribution during friction stir welding of similar and dissimilar Aluminium grades
are predicted through Cellular Automata Finite Element (CAFE) modelling. For similar material, the
average grain size is about 5.85 m in the nugget zone. The grain size obtained by CAFE modelling and
grain size given in the available literature are almost same. For dissimilar FSW material, it is found that
temperature fields are distributed asymmetrically resulting in larger thermal affected zone in the AA6061
side. It is seen that average difference between experimental and simulation result is about 25±10°C. The
predicted grain size through CAFE modelling agrees well with the available results in the case of dissimilar
grade combinations.
Key-words: Friction stri welding, CAFÉ, Temperature
Resistance Welding of Austenitic Stainless Steels (AISI 304 with AISI 316)
A.B.Verma1*, S.U. Ghunage2 and B.B.Ahuja3
Shree Ramchandra College of Engineering, Pune,412207,
2
College Of Engineering,Pune,411005,
3
College Of Engineering,Pune,411005,
1*
Resistance spot welding (RSW) has a very important role as a joining process in the automotive industry
and a typical vehicle contains more than 3000 spot welds. The quality and strength of the spot welds are
very important to the durability and safety design of the vehicles. The development of the new materials
results constantly in the resistance spot welding tasks with new materials or combinations of them. The lack
of experience with the new materials or combinations of them often results in the use of the welding
parameters which are not optimal. A few common guideline values and weldability diagrams for spot
welding of steels exist and most of the guidelines are for non stainless steels each spot welding is not
performed on the same condition because of the alignment of sheets and electrodes as well as the surface
condition. For that reason, a spot welding process needs the optimum process condition that can afford
allowance in parametric values for good quality of welding. In this paper ASS 304 and ASS 316 is used and
its tensile strength and hardness is studied by using Taguchi approach and ANOVA while microstructure is
studied by Schaeffer diagram.
Keywords: ANOVA, Austenitic stainless steel, Taguchi method.
Experimental Study on Temperature Evolution During Friction Stir Welding of 6061T6 Aluminum alloy
Perumalla Janaki Ramulu1* and R. Ganesh Narayanan2
1
Vardhaman College of Engineering, Shamshabad, 501208,
2
Department of Mechanical Engineering, IIT Guwahati, Guwahati, 781039,
This study aims to explore the temperature evolution during friction stir welding of Aluminum 6061-T6
under different process parameters like plunge depth; tool rotation speed; and welding speed with three
different tool shoulder diameters. Thermocouples were inserted in the pre-holed work-pieces. These
positions were decided based on experimental trials. The welded joints were made such that they are free of
internal defects. Temperature histories were measured using thermocouples during FSW at specified
locations on the work-piece in the welding direction. Experimental results show that by increasing the
plunge depth, tool rotation speed, the maximum temperature is increased, whereas it is opposite for welding
speed.
Keywords: Friction stir welding, Welding speed, Tool rotation speed, Temperature
Effect of Process Parameters on Angular Distortion of Mig Welded Ai6061 Plates
Ramani, S.1* and Velmurugan, V.2
1*
Avinashilingam University for Home Science and Higher Education for Women, Coimbatore – 641 043,
2
SreeSakthi Engineering College, Coimbatore – 641 104,
Angular distortion is one of the most challengeable issues and pronounced distortion among different types.
This is mainly due to non uniform traverse shrinkage along the depth of the plate welded. Physical
controlling of the distortion during welding may generate high magnitude of residual stress. However, these
can be reduced by compensating with pre-distortion in the opposite direction to actual distorting direction
with the experience of series of experiments. In this study, a statistical method with four factors and five
level factorial centre composite rotatable design is used to develop a mathematical model to predict angular
distortion with MIG welding process parameters. Direct and interaction effects of the process parameters are
analyzed. The developed mathematical model could be utilized for optimizing the MIG process parameters
by eliminating the defects due to angular distortion.
Keywords: Angular distortion, MIG welding, Central composite, Rotatable design
Application of Genetic Algorithm to Optimize Properties of Pulsed Current Micro
Plasma Arc Welded Inconel 625 Sheets
Kondapalli Siva Prasad1*, ChalamalasettiSrinivasa Rao2, DameraNageswara Rao3 and
ChintalaGopinath4
1*
Anil Neerukonda Institute of Technology & Sciences, Visakhapatnam, India
2
AU College of Engineering, Andhra University, Visakhapatnam, India
3
Centurion University of Technology & Management, Odisha,India
4
Guru Nanak Institutions Technical Campus, Hyderabad,India
1*
Corresponding Author Email:[email protected]
Pulsed Current Micro Plasma Arc Welding (PCMPAW) is commonly used for joining thin sheets where
Laser beam and Electron Beam welding are not economical. The quality of welded joint depends on the
grain size, hardness and ultimate tensile strength, which have to be properly controlled and optimized to
ensure better economy and desirable mechanical characteristics of the weld. This paper highlights the
development of empirical mathematical equations using multiple regression analysis, correlating various
welding parameters to grain size, hardness and ultimate tensile strength in PCMPAW of Inconel 625 sheets.
The experiments were conducted based on a five factor, five level central composite rotatable design matrix.
Genetic Algorithm (GA) is adopted to optimize the process parameters for achieving the desired grain size,
hardness and ultimate tensile strength.
Keywords: Inconel 625, pulsed current, Micro Plasma Arc Welding, Genetic Algorithm
Mechanical and Microstructural Characterization of Friction Stir Welded Al-Si-Mg
Alloy
Vikas Sharma1*, Shailendra Singh2, Chaitanya Sharma3 and Vikas Upadhyay4
1*
Anand Engineering College, Agra, 282007,
2
HITM College, Agra, 282007,
3
Rustamji Institute of Technology, Gwalior, 475005,
4
IMS Engineering College, Ghaziabad, 201009,
Friction stir welding of Al-Si-Mg alloy was performed in butt joint configuration using varying welding
speed and constant rotary speed. Tensile tests were performed to determine ultimate tensile strength, yield
strength and % elongation. Microstructure was investigated using optical and scanning electron microscope.
Micro hardness measurements across the transverse cross section of FSW joints were carried out to identify
variations in micro hardness in different zones. An optimum combination of welding and rotary speed (120
mm/min and 635 rpm) was obtained to produce sound and defect free FSW joints that yields maximum
mechanical properties. An increase in welding speed first increased the ultimate tensile strength, and yield
strength of FSW joints while % elongation decreased with increase in welding speed. Welding speed
influenced the mechanical properties and mode of fracture of FSW joints.
Keywords: Friction stir welding, Al-Si-Mg alloy (AA6101), Microstructure & Mechanical properties,
fracture location
Finite Element Simulation of Temperature and Strain Distribution in Al2024
Aluminum Alloy by Friction Stir Welding
Rahul Jain1*, S.K. Pal2 and S.B. Singh3
2
3
Department of Metallurgical and Material science, IIT Kharagpur, 721302,
1
Friction stir welding (FSW) is a solid state joining process and is handy for welding aluminum alloys.
Numerical simulation of FSW is highly complex due to non-linear contact interactions between tool and
work piece and interdependency of displacement and temperature. In the present paper a three dimensional
finite element model is proposed to study the thermal history, strain distribution and thermo-mechanical
process in butt welding of Aluminum alloy 2024 using DEFORM-3D software. Effect of tool rotational
speed on plastic strain is studied and insight is given on asymmetric nature of friction stir welding process.
Lagrangian incremental technique is used to model FSW process and sticking condition is defined between
tool and work piece.
Keywords: Friction stir welding, Finite element method, Temperature distribution
Study on the Novel Twin-Tool System on Heat Treated Commercially Pure Aluminium
Alloy in Friction Stir Welding Process
Kanchan Kumari1, S.K. Pal2 and S.B.Singh3
2
3
Department of Metallurgical and Materials Engineering, IIT Kharagpur, 721302,
1
In this work, a twin tool set-up is designed, fabricated and is used to investigate the performance.
Experiments were performed using twin tool on non-heat treated and heat treated commercially pure
aluminium alloys and tensile test properties were studied over the cross-section of the weld. It is seen that
after heat treatment both yield strength and UTS comparatively decrease due to increase of ductility i.e.
percentage of elongation. Further using twin tool with the same process parameter, heat-treated aluminium
alloy shows further decrease in UTS, and YS and increase in percentage of elongation compared to non-heat
treatable aluminium alloy.
Keywords: counter-rotating twin tool, friction stir welding, heat treatment
Regression Modeling and Process Analysis of Resistance Spot Welded Joints
Sreenu, S.1*, Kishore, N.2, Ramachandran, N.3 and Allesu, K.4
National Institute of Technology Calicut, 673601
1*
2
3
4
In this study, the effects of weld current, weld time, electrode force and combination of these on the nugget
diameter, heat affected zone and tensile-strength of welding joint in electrical resistance spot welding of
AISI 304 sheets of 1mm thickness are investigated. A timer and current controlled pneumatically operated
rocker arm type spot welding machine of 10 kVA capacity with pneumatic application mechanism and foot
switch, with controls for weld current periods, weld time periods and electrode force is used. Squeeze time
is kept constant throughout the process at 40 cycles. The obtained welded joints are subjected to tensileshear strength. Nugget diameter and heat affected zone (HAZ) are observed and computed. The effect of
weld current, weld time and electrode force on nugget diameter, HAZ and tensile-shear are then researched
by regression modeling and by related diagrams. Optimum weld current, weld time and electrode force for
various configurations are thus arrived at.
Keywords: Tensile–shear strength, heat affected zone (HAZ), AISI-304 Sheet, Regression modeling
Paper #AIMTDR-O0528(Poster)
Parametric Analysis of Friction Stir Welding
Suyash Tiwari1*, H. Chelladurai2 andAshish Kumar Shukla3
1, 2,3
PDPM Indian Institute of information Technology,
Design and Manufacturing, Jabalpur, India
E-mail: 3ashish.shukla@ iiitdmj.ac.in
Friction stir welding (FSW) uses a non consumable tool to produce frictional heat in the adjoining surfaces.
The welding parameters like rotational speed, welding speed, tool pin length, and tool shoulder diameter
play a major role in deciding the joint properties. In this work, an attempt has been made to analyze the
effect of various tool profiles on mechanical properties of aluminum alloy. Various tool profiles have been
used to fabricate joints by using constant thickness (3mm) work piece of aluminum alloy. The mechanical
properties of welded materials are measured in-terms of tensile strength and Brinell hardness number
(BHN). By using Design of Experiment (DOE) concept, experiments were carried out to predict tensile
strength and BHN of the welded joint. In this work, heat generated during the process is utilized to improve
the quality of welded joint by using backing plate (low thermal conductivity or insulating material) between
workpiece and fixture. By varying the welding parameters, effect on joining efficiency in terms of gap
between two mating surfaces on the back side of the welded plate has been analyzed. From this
investigation, it has been found that tool profile (shoulder dia. 18 mm, pin length 2.8 mm) produces good
tensile strength.
Keywords:AA6063 aluminium alloy, friction stir welding, BHN.
Numerical Analysis of Heat Transfer of Arc Welded Plate
1
Aniruddha Ghosh1, Pawan Kumar2 and Arvind Kumar2*
Dept. of Mechanical Engineering, Govt. College of Engineering & Textile Technology, Berhampore, WB,
India
2
Dept. of Mechanical Engineering, Indian Institute of Technology, Kanpur, UP, India
2*
corresponding author, E-mail: [email protected]
In submerged arc welding process, the understanding of temperature distribution is essential in order to control
the dimension of heat affected zone and to get the required weld bead shape and size etc. Moreover, the
temperature profile is required to estimate the stress distribution in thermo mechanical analysis of the process.
In this work, a numerical solution for moving heat source with Gaussian distribution of heat flux density over
the volume of oval shape is derived using finite difference method. Heat transfer in welded plates during
welding from fusion zone to heat affected zone (HAZ) is assumed to be conductive heat transfer. Convective
and radiative heat losses are also considered for remaining zone of welded plate. With the help of the
numerical solution, transient temperature distribution is estimated. HAZ widths are also measured
experimentally. Decent agreements between predicted and experimental values are achieved.
Keywords: Submerged arc welding, Gaussian heat distribution, Oval heat source, Finite difference method
Development and Analysis of Butt and Lap welds in Micro Friction Stir Welding
(µFSW)
Shuja Ahmed1, Abhishek Shubhrant2, Akash Deep3 and Probir Saha4*
Department of Mechanical Engineering, Indian Institute of Technology Patna, Patna 800013,
2
3
4*
Department of Mechanical Engineering, Indian Institute of Technology Patna, Patna 800013, E-Mail:
[email protected]
1
Manufacturing of the ever smaller components, be it mechanical, electronic, etc. is being chased upon. Also
in friction stir welding (FSW), when the thickness of the joining plates is reduced to less than 1 mm i.e.,
micro friction stir welding (µFSW), the application areas relate to joining thin walled structures in electrical,
electronic and micro-mechanical assemblies and in the packaging industry. Advantages of FSW like its
being a solid state process, it not requiring shielding gases and fluxes and its possibility to weld dissimilar
and different thickness alloys emphasize the use of it to weld micro thickness plates. In the present work,
commercial grade AA6XXX series aluminium alloys of thickness 0.44 mm have been welded together in
both butt and lap fashion. Tests have been conducted to measure the joint’ s tensile strength (by conducting
both transverse and longitudinal tension tests) and the micro hardness. The use of lap welds in application
areas of µFSW was established.
Keywords: micro friction stir welding (µFSW), butt and lap fashion, tensile strength, micro hardness
Effect of Different Experimental Parameters Observation through Simulation of Tailor
Welded Blanks Made of Friction Stir Welding
1
Aruna Jyothi1, Monika Sharma1 and Perumalla Janaki Ramulu2*
Department of Mechanical Engineering, Holy Mary Institute of Technology & Science, Hyderabad
2*
Department of Mechanical Engineering, Vardhaman College of Engineering, Hyderbad-501218,
In the current scenario, the automobile industries are focusing on weight reduction of the automotive body
which can improve the fuel efficiency orally. This as motto, many researchers are working on many
engineering materials and their joining techniques to reduce the weight reduction for better fuel efficiency.
To co-ordinate this, there is tailor welded blanks (TWB) technique is highly recommended by researchers
and many automobile industries have been adopted the technology. In the present work, the main aim is the
forming behavior of the TWBs made of friction stir welding (FSW) process under two different welding
speeds (90 mm/min and 100 mm/min). The forming simulations were conducted using the limiting dome
height (LDH) test. For the simulation 8 strain paths with minimum size of 25×200 mm to maximum size of
200×200 mm were considered. Forming limit diagrams of base metal, FSW sheets are plotted and
compared. From simulation results, it has noted that FSW sheets have more formability than the base
material. FSW sheet fabricated at 90 mm/min welding speed has noted better formability than 100 mm/min
welding speed FSW sheet.
Keywords: Forming limit diagram; FSW sheets; welding speed
Prediction of Bead Reinforcement Height and Width of Gas Tungsten Arc Welded
bead-on Plate Joints Using Artificial Neural Network
Rajeev Kumar1, Somnath Chattopadhyaya2 and Sanjeev Kumar3
Department of Mechanical Engineering, ISM, Dhanbad (JH.), India-826004
1
2
Department of Mechanical Engineering, ISM, Dhanbad (JH.), India-826004
2
3
Department of Mechanical Engineering, IIMT, Gr. Noida, India-201306
3
1
A number of welding parameters are responsible for the quality of welds. The modeling of weld bead shape
is important for predicting the quality of welds. In this paper, an attempt has been made to develop a backpropagation neural network (BPNN) model for the prediction of reinforcement height and width of bead in
GTA bead-on plate welding process. The experimental results were used as testing sample for BPNN
model. Welding current and welding speed were considered as the input parameters and bead reinforcement
height and bead width were response parameters in the development of the BPNN model. The percentage
errors (%) for all the samples were calculated to validate BPNN model. The result was found that the BPNN
model developed in the present research work can predict the responses selected with good agreement
Keywords: Weld bead, back-propagation neural network, modeling etc.
Evolution of Temperature Field Developed in Arc Welded Steel Butt Joints and its
Effect on Cooling Rate: An Experimental and Mathematical Approach
Jaideep Dutta1*and Narendranath S.2
Department of Mechanical Engineering, National Institute of Technology Karnataka, Surathkal, Mangalore
2
Department of Mechanical Engineering, National Institute of Technology Karnataka, Surathkal, Mangalore
1
In present work, an integrative comprehensive study has been portrayed to determine the temperature
distribution along the longitudinal direction of rectangular butt joint from the weld bead. A mathematical
model incorporating temperature dependent thermal conductivity along with constant heat generation, is
developed using Adomian Decomposition method (ADM) to analyse temperature distribution.
Experimentation has been carried out by mounting K-type thermocouple in the rectangular plate of AISI
1040 at predefined locations. The experimental readings and mathematical model has been validated by
empirical correlation of peak temperature equation. To investigate the cooling rate Rosenthal’ s 3D model
has been utilized for derivation of cooling rate along the longitudinal direction of rectangular workpiece.
The study of microstructure also has been carried out for uniform and non-uniform cooling rate.
Experimentally it was found out that temperature loss is very severe near the surface of weld pool (800°C 1400°C) whereas it remains steady on the rear end of the plate due to transient nature. The analytical model
as derived by Adomian decomposition method, entails that the temperature distribution is very gradual
along the longitudinal direction from the weld bead.
Keywords: Adomian decomposition method, cooling rate, transient temperature field, butt joint
Experimental and Analytical Study of Thermally Induced Residual Stresses for
Stainless Steel Grade Using GMAW Process
M.N.Chougule1*and S.C.Somase2
Sinhgad Institute of Technology, Lonavala,Pune-410401,
2
Sinhgad Institute of Technology, Lonavala,Pune-410401,
1*
Gas metal arc welding (GMAW) controls the metal from the wire rod by developing the arc as well as by
controlling the input process parameters. High heating at a one location during welding and further rapid
cooling generates residual stress and distortion in the weld and base metal. In the last few decades, various
research efforts have been directed towards the control of welding process parameter aiming at reducing
residual stress and distortion they are strongly affected by many parameters like structural, material and
welding parameters. Such welding failure can be minimized by controlling the weld heat input. The
distribution of the temperature in weld joint of AISI202 grade high strength steel is investigated by Finite
Element Method (FEM) using ANSYS software and experiment has been performed to verify the developed
thermo-mechanical finite element model using the GMAW process. Basic aim of our paper is to analyse
temperature distribution and residual stresses in dissimilar metal welded plates to avoid future failure in
material because experimental process is costly. The behavior of weld zone is affected by variation in
temperature distribution, microstructure and mechanical properties of the material. The residual stress
gradient near the fusion zone is higher than in any other location in the surrounding area. Because of this
stress gradient, cold crack at the fusion zone in high strength steel occur. The main objective of this
simulation is the determination of temperatures and stresses during and after the process. Temperature
distributions define the heat affected zone (HAZ) where material properties are affected. Stress calculation
is necessary because high residual stresses may be caused fractures, fatigue which causes unpredictable
failures in regions near the weld bead region.
Keywords: GMAW, FEM, Transient Thermo-mechanical simulation, Residual stress.
Prediction of Weld Bead Geometry for Double Pulse Gas Metal Arc Welding Process
by Regression Analysis
MainakSen1*, Manidipto Mukherjee 2 and Tapan Kumar Pal 3
IIT Kharagpur, Kharagpur, India, 721302.*Corresponding author. E-mail: [email protected]
2
Jadavpur University, Kolkata, India, 700075.
3
Jadavpur University, Kolkata, India, 700075.
1*
Double Pulsed GMAW (DP-GMAW) has been recognized as a new and efficient technique for quality
welding. The double-pulsed GMAW (DP-GMAW) technique is a variation of the pulsed GMAW technique,
in which the pulsing current aimed to metal transfer control is overlapped by a thermal pulsation, which in
turn means pool control. The weld bead plays an important role in determining the mechanical properties of
the weld. Its geometric parameters, viz., width, reinforcement height, and penetration, are decided according
to the welding process parameters. Therefore, to produce good weld bead geometry, it is important to set the
proper welding process parameters. In this study, the regression modeling is used in order to establish the
relationships between input and output parameters for DP-GMAW. To gather the required data for
modeling, actual tests were carried out based on the proposed Taguchi experimental matrix design. The
purpose of this study is to find a regression model of the welding process parameters in order to obtain the
desired geometry. The adequacies of the models are then evaluated using analysis of variance (ANOVA)
technique. The model developed was checked for their adequacy. Results of confirmation experiments
showed that the model can predict the bead geometry with reasonable accuracy.
Keywords: DP-GMAW; Bead geometry; Taguchi method; Regression analysis.
Experimental Investigations on Plasma Arc Welding of Lean Supermartensitic
Stainless Steel
1
Birendra Kumar Barik, 1*P. Sathiya and 2S.Aravindan
Department of Production Engineering, National Institute of Technology
Tiruchirappalli-620015, Tamilnadu, India.
2
Indian Institute of Technology Delhi, New Delhi-110016, India
*Corresponding author E-mail: psathiya @ nitt.edu; Tel.:+91 431 2503510; Fax: +91 431 2500133
1
Nowadays the lean super martensitic stainless steel (LSMSS) becomes an economical alternative to the
traditional carbon and/or austenitic-ferritic (duplex) stainless steel for the construction of pipelines in
transport of gas and corrosive oils. Lean super martensitic stainless steel exhibits higher toughness,
corrosion resistance and weldability properties when compared to conventional martensitic stainless steel.
The main purpose of this study is to investigate the mechanical and metallurgical properties of welds made
by the keyhole mode of plasma arc butt welded joints. The macrostructure and microstructure were
evaluated through optical microscope. The mechanical properties such as tensile and impact tests were
carried out at room temperature and their fractured surfaces were also analysed through scanning electron
microscope (SEM). The corrosion resistance of the weld is determined by electro chemical analysis using
Tafel plot and the same is correlated with their microstructures.
Keywords: Lean super martensitic stainless steel, Mechanical and Metallurgical characterization, Corrosion
resistance
Abstracts of Advanced
Manufacturing-I Papers
Optimization of Dimensional Devaition: Wire Cut EDM of Vanadis- 4E (Powder
Metallurgical Cold Worked Toolsteel) By Taguchi Method
D.Sudhakara1* and G. Prasanthi2
1*
Dept. of Mechanical Engineering, Siddartha Institute of Science & Technology, Puttur, Andhra Pradesh,
India-517583, [email protected]
2
Dept. of Mechanical Engineering, JNTUA College of Engineering, Ananthapuramu, Andhra Pradesh,
India-515002, [email protected]
Wire electrical discharge machining is the trendiest advanced manufacturing process to manufacturer
sophisticated components, moulds and dies with very good dimensional accuracy. The main aim of this
experimental work is to find out optimal process parameters to reduce dimensional deviation as compared to
required dimensions. The process parameters of this Wire electrical discharge machining is pulse on time,
pulse off time, peak current, spark gap set voltage, wire tension and water pressure .The orthogonal array of
L27 Taguchi design is used to plan conduct the experiments. The ANOVA is employed to find out the
effects of process parameters on dimensional accuracy. The process parameters are optimized in order to
minimize the output response i.e. dimensional deviation. The VANADIS 4E (powder metallurgical cold
worked tool steel) is used for experimental work and the experiments are conducted on WEDM set up of
ELECTRONICA ULTIMA-1F.
Keywords:Wire electrical discharge machining, VANADIS 4E (powder metallurgical cold worked tool
steel), Taguchi method, Dimensional Deviation, ANOVA.
Prediction of Thermal History of Friction Stir Welding by Considering Combined Stick and Slip
Condition of AA1100
Arun Kumar Kadian1, Gautam Puri2 and Pankaj Biswas3*
Mechanical Engineering, IIT Guwahati 781039, E-mail: [email protected]
2
3*
1
In the present work three-dimensional Finite Element (FE) transient thermal analysis of friction stir welding
have been presented. It was observed that most of the research on thermal history analysis of Friction Stir
Welding (FSW) considered only frictional heat generation. In this present work the source of heat
generation have been assumed to be both friction between the tool and work piece interface and shear
deformation of material. A comparative study has been done between thermal history prediction by heat
generation due to friction and heat generation due to both friction and shear deformation of material. The
numerically predicted thermal profiles compared well with those of the experimental results with less error
thus validating the various assumptions made in the work.
Keywords: Finite Element analysis, Transient Thermal analysis, Combined Stick & Slip condition, Friction
Stir Welding.
Effect of Tool Geometry and Process Parameters on the Material Flow of Friction Stir
Welding
Arun Kumar Kadian1, Gautam Puri2, Suman Das2 and Pankaj Biswas3*
1
2
2
3*
The material flow behavior of friction stir welding is an emerging research area in past few years. In this
present work two different tool geometries has been considered to study the material flow patterns of the
welding process. A 3-D CFD analysis is performed with suitable boundary conditions to study the nature of
material flow behavior of FSW process. A comparative study has been done based on the results obtained
from numerical analysis for the two different tool geometries. The parameters used for the analysis of
welding process also varied one by one for both the cases to achieve a good comparison on the effect of tool
geometry on the material flow. The estimated material flow behavior compared well with those of the
published results thus validating the various assumptions made in the work. It was observed that in FSW
tool geometries has significant effect on material flow behavior.
Keywords: Finite Element Analysis, Transient Thermal Analysis, Combined Stick & Slip Condition,
Friction Stir Welding.
Finishing of Synchrotron Beamline Mirrors
1
Ajay Sidpara1*, V. K. Jain2 and G. S. Lodha3
Mechanical Engineering Department, Indian Institute of Technology Kharagpur – 721302, India
2
Mechanical Engineering Department, Indian Institute of Technology Kanpur – 208016, India
3
Indus Synchrotrons Utilisation Division, Raja Ramanna Centre for Advanced Technology, Indore –
452013,
*E-mail: [email protected]
Synchrotron radiation beamline is used for carrying out research on X-ray based techniques. A wide variety
of beam lines are being developed for extending the applications in micro / nano domains of medical
science, physics, semiconductor, optics, material science and many more. X-ray mirrors are essential
component of any such beamline for guiding the X-ray beam and focusing it to a particular location.
Different shapes of mirrors such as flat, cylindrical, elliptical and toroidal are generally used in the
beamlines. Slope error in micro radian and surface roughness in a few Å (< 3) are the prime requirements
for good focusing properties of synchrotron beam and good reflectivity of X-ray beam.
The above requirements and stringent control over the surface figures make the fabrication and finishing of
these mirrors very challenging and extremely difficult. Fabrication and finishing of mirrors consist of loops
of different process steps with intermediate metrology stages. The loops are continued until the surface
attains the desired specification level. Due to very stringent requirements of surface roughness and figure
accuracy, only few processes are used for fabrication of these mirrors. A brief overview of different
finishing processes is given in this paper. A few processes are discussed in depth and a hybrid finishing
process is proposed for finishing of mirrors.
Keywords: Synchrotron radiation, Silicon mirrors, Magnetorheological finishing, Elastic emission
machining, Abrasive particles
Experimental Study into Groove Machining Using Rotary Disk Electrical
Discharge Machining With Silicon Powder-Mixed Dielectric
Shankar Singh1* and Anand Pandey2
SantLongowal Institute of Engineering & Technology, Longowal-148106
2
School of Engineering & Technology
Manipal University, Jaipur
1*
In the present study, an effort has been made to generate grooves on Nimonic75® super alloy with rotary
copper disk of varied aspect ratio through powder-mixed EDM. Taguchi’ s orthogonal array L18 (21×37) has
been adopted to investigate the effects of one noise factor viz. aspect ratio with two levels and seven control
factors namely peak current, pulse on time, pulse off time, gap voltage, rotational speed, powder particle
size and powder particle concentration with three levels each, on responses namely material removal rate
and surface roughness. In addition, micro-structural studies via SEM and XRD has been performed of the
machined surface. On the basis of results obtained, it was found that aspect ratio; peak current, rotational
speed and powder particle concentration plays a significant role in improvement of the machining
characteristics. The results revealed significant performance improvement with the powder-mixed dielectric.
Keywords: Superalloys, RD-EDM, Powder-mixed fluid, Optimization
Thermal and Metallographic Investigation for H13A and AISI1050 using Vortex Tube
Jet Assisted (VTJA) Machining
Balaji Nelge1*, Kiran Devade2, A.T. Pise3 and V.M. Kale4
ICEM, Parandwadi, 410506, [email protected]
2
ICEM, Parandwadi, 410506,[email protected]
3
DTE, Maharashtra, 411004, [email protected]
4
ICEM, Parandwadi, 410506, [email protected]
1*
Machining without the use of any cutting fluid is known as dry or green machining. It is becoming
increasingly more popular due to concern regarding the safety of environment. Most industries apply cutting
fluids/coolants when their use is not necessary. The coolants and lubricants used for machining represents
16–20% of the manufacturing costs, hence the unnecessary use of these fluids should be restricted.
Moreover there are certain materials that are considered as difficult to machine, for machining of such
materials dry machining is advisable.An attempt is made here to carry out study with dry, wet as well as dry
machining using cold air stream coming out of vortex tube, and the work piece is analyzed thermally as well
as metallographic ally. The results are promising and have shown better results for cold air machining using
vortex tube. The machining is performed using two grades of materials namely H13A, and AISI1050 with
carbide coated tools, with depth of cut of 0.2 mm, Feed rate fixed at 0.5mm/rev and cutting speeds of
250,400,600 rev on semiautomatic lathe machine.The tests are conducted with coolant, without coolant and
with cold air stream as coolant, After the tests the thermal plots and metallographic study for hardness and
surface finish have revealed that using cold air as coolant produces better surface finish while maintaining
the tool tip and work surface at significantly lower temperatures. The same is being termed here as Vortex
Tube Jet Assisted (VTJA) machining.
Keywords: Dry machining, Green machining, Vortex Tube Jet Assisted (VTJA) machining
Analysis of Magnetic Field Assisted Finishing (MFAF) Process Parameters for
Finishing Brass Workpiece Using Soft-Computing Technique
Anwesa Barman1, Chandan Kumar2 and Manas Das3*
Mechanical Engineering Dept., IIT Guwahati, Guwahati, 781039, [email protected]
2
3
1
Magnetic Field Assisted Finishing (MFAF) process is a precise nanofinishing process. Magnetorheological
(MR) fluid is the main element in MFAF process. In these process two types of motion, rotational and
reciprocation is provided to the MR fluid to get uniform smooth finished surface. Brass is used as the
workpiece. The input process parameters are extrusion pressure, number of finishing cycles, rotational speed
of the magnet, and volume ratio of carbonyl iron particle (CIP) and silicon carbide (SiC) in the medium. The
output process parameter is percentage change in surface roughness. In this study the relationship between
the input and output process parameters of MFAF is established using Backpropagation neural network
technique. Also a close comparison has been made between the regression analysis model and neural
network model of the process parameters. From the simulation results, it has been found that the neural
network model yields a more accurate result than the regression analysis method. Further an optimization
study has been carried out to optimize the input process parameters to get maximum output. Genetic
algorithm (GA) technique is used as the optimization technique considering regression equation model as
the objective function. The optimized process parameters agree well with the experimental results.
Keywords: Nanofinishing process, Neural Network, Genetic Algorithm.
Modeling and Simulation of Magnetic Field Assisted Finishing Process
Anwesa Barman1, Manas Das2*andAnkur Singh3
IIT Guwahati, Guwahati, 781039, [email protected]
2
IIT Guwahati, Guwahati, 781039,[email protected]
3
1
Magnetic field assisted finishing (MFAF) process is an advanced finishing process. This process is capable
of producing nanometer level surface finish. Magnetic field is used to control the MFAF process using
magnetorheological (MR) polishing medium. In this study, permanent magnet is used to provide the
magnetic field in the finishing zone. The working gap between the workpiece and the magnet is filled with
MR fluid which is used as the polishing brush to remove surface asperities from the top surface of the
workpiece. In this paper, a finite element model of the process is developed to assess the distribution of
magnetic field and its direction on the workpiece surface using Ansoft Maxwell® FEM package. Later, the
magnitude of magnetic force is calculated for the modelling of material removal and surface roughness
improvement during MFAF process.
Keywords: Nanofinishing process, MR fluid, Magnetic field assisted finishing.
Modeling of Finishing Forces and Surface Roughness in Abrasive Flow Finishing (AFF)
Process using Rheological Properties
Sachin Singh1, M. Ravi Sankar1*, V. K. Jain2 and J. Ramkumar2
1*
Department of Mechanical Engineering, IIT Guwahati, Guwahati, 781039, India.
2
Department of Mechanical Engineering, IIT Kanpur, Kanpur, 208016, India.
1
Email: [email protected], 1*[email protected], [email protected], [email protected]
The final operation performed in most of the manufacturing process is finishing. As the requirement of
surface finish increases the cost of the product escalates exponentially. Abrasive flow finishing (AFF) is one
of the advanced nano finishing technologies, which is specifically used to finish simple and complex surfaces.
In the present work, rheological properties of the polymer based medium are evaluated using MCR 301
parallel plate rheometer. Then the axial and radial finishing forces in AFF process developed during finishing
action are determined from rheological properties of the medium. The finishing forces are used to find the
depth of cut/penetration of the active abrasive particle in the given initial surface. Later, the theoretical model
of the surface roughness is developed and model results are compared with the experimental results.
Keywords: Nano-finishing; Abrasive flow finishing, Deburring
Effect of direct current and pulse current on processing time, electrolyte composition
and electrolyte concentration of electrochemical honing
H. Singh*and P.K. Jain
Department of Mechanical and Industrial Engineering,
Indian Institute of Technology Roorkee, Roorkee-247667, Uttarakhand,
The effects of processing time, electrolyte composition and electrolyte concentration on the electrochemical
honing (ECH) performance under direct current and pulse current condition were studied. ECH is a hybrid
machining processes used for finishing internal cylinders, gun barrels and gears, based on the combination
of electrochemical machining (ECM) process having high material removal capability and controlled
functional surface generating capability of conventional honing process in a single operation. It is reported
that the material removal rate of ECH is two to eight times higher than the conventional gear finishing
processes and can provide better surface finish value to Ra 0.05 mand hence its benefits can be widely used
for aerospace, automobile, gear manufacturing, nuclear reactor applications etc. Moreover, the pulse
assistance in ordinary ECH provides the relaxation period to the ECM zone of the system during pulse-off
time to discharge the dregs out of the inter electrode gap and thus improves the process capability for
maximizing the service life and overall performance of gears. Based on the experimental findings at the
optimum setting of input process parameters, pulse current shows an improvement of 22.73 percent in
average surface roughness and 13.48 percent in maximum surface roughness value of EN8 spur gear as
compared to direct current. SEM images have revealed that finished surface having uniform structure and
free of scratches and micro-cracks.
Key words: Electrochemical honing (ECH), Pulse and direct current, Spur gear
Investigation of Machining Characteristics of Electrochemical Micromachining
Machine (EMM)
Thanigaivelan. R1*, Arunachalam.RM2and Natarajan.N3
1
*Department of Mechanical Engineering
Muthayammal Engineering College, Rasipuram
2
Department of Mechanical and Industrial Engineering
College of Engineering, Sultan Qaboos University,Sultanate of Oman
3
Muthayammal College of Engineering, Rasipuram
To make use of full capability of Electrochemical Micro-Machining (EMM), a meticulous research is
needed to improve the material removal, surface quality and accuracy by optimizing the various EMM
process parameters. Keeping this in view, an indigenous development of EMM machine set-up has been
considered to carry out a systematic research for achieving the satisfactory control on EMM process
parameters to meet the micromachining requirements. In this study an EMM machine has been developed
and experiments were conducted to study the influence of some of the major process parameters such as
machining voltage, electrolyte concentrations, pulse on time and machining current on machining rate and
accuracy. The effect of shape of the tool electrode tips on EMM has been investigated experimentally with
304 Stainless Steel (SS) sheets. The machining rate and overcut are significantly influenced by the shape of
the tool electrode tips.
Keywords: Electrochemical micromachining, 304 stainless steel, Machining rate, Overcut, Tool Tip Shape.
Selection of Non-Conventional Manufacturing Process: A Combine
Topsis-AHP Approach
Ashish Chauhan* and M. K. Pradhan
Maulana Azad National Institute of Technology, Bhopal, 462001,
Email: [email protected], [email protected]
With increasing usage of high strength material like titanium, ceramics, composite material, stainless steel
in different field such as aerospace, nuclear, and steam turbine, which have generally high strength, high
hardness is usually processed by various Non-Traditional Manufacturing (NTM) processes. But these NTM
processes consume high power and are too expensive, hence necessitates one optimum NTM process for a
given material for economical machining. However, the selection of optimum process is a tedious task. It
consists of various factors that influence the selection method of machining process. A combine method
using the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) and an “ Analytical
Hierarchy Process” (AHP) is suggested to select the most suitable non-traditional process for given material
and shape feature combination while taking various attributes affecting the NTM selection determination.
By the help of combining TOPSIS an AHP method which is based on comparison between various
attributes and secondly based on fact that best alternative has least geometric distance from ideal solution
and worst alternative has more geometric distance from an ideal solution. After applying combine approach
among the available NTM processes viz. USM, WJM, AJM, ECM, CM, EDM, WEDM, EBM, LBM, PAM,
AFM, it is found that PAM is a best available process to work with steel material followed by ECM, EDM
and EBM respectively.
Keywords: Technique for order preference by similarity to ideal solution, Analytical hierarchy process,
Non-traditional machining process.
Multi-Response Analysis of Electro-Chemical Machining Process Using Principal
Component Analysis
K. P. Maity* and N. K. Verma
National Institute of Technology, Rourkela-769008
Electrochemical machining is one the best alternative for producing complex shapes in advanced materials
used in aircraft and aerospace industries. The process is influenced by different parameters including tool
and work-material. In the present investigation the electrochemical machining has been carried out taking
mild steel as work material and copper as tool material. The optimization of the process parameters has been
carried out to satisfy the multi-objective response criteria such as overcut and circularity error using
Principal Component Analysis.
Keywords: Machining, Electrochemical machining, Optimization
Fabrication of Complex Circuit Using Electrochemical Micromachining on Printed
Circuit Board (PCB)
Singh Jitendra1, Jain V.K.2*and Ramkumar J.3
Mechanical Engineering Department, IIT Kanpur - 208016, [email protected]
2*
3
1
Electrochemical micromachining (ECMM) is an advanced machining process for machining of electrically
conducting materials. In the present work, an experimental set-up for electrochemical micromachining
(ECMM) is used to fabricate complex circuits on printed circuit board (PCB) by using masking technique.
Mask is made using 50 µm transparency sheet cut by laser beam. This mask is bonded on printed circuit
board of cross section 35 mm X 35 mm by a water insoluble glue Araldite (epoxy adhesive). For the
analysis of the data the channel width of the circuit structure is measured with the help of photographs taken
by using Dinolite capture and optical microscope. For this purpose whole structure is divided into 4 regions,
which have fifty eight points in which width has been measured. For the analysis of the depth of a channel, a
dial gauge having 1 m least count is used to measure the depth at different sections (or regions) as marked
in the Figure. For this purpose, the whole structure is divided into 4 regions, which have twenty seven
points. After all the experiments have been completed, the circuit is compared with the main circuit which is
fabricated by milling process and % error in the circuit is evaluated.
Keyword: Electrochemical micromachining, Printed circuit board, micromachining
Simultaneous Modeling of Responses in AWJM of Borosilicate Glass by SVM and
SEM Study
Ushasta Aich1, Simul Banerjee 2*, Asish Bandyopadhyay3 and Probal Kumar Das 4
1, 2 , 3
* Mechanical Engineering Department
Jadavpur University
Kolkata 700032, India
4
Non-oxide Ceramic and Composite Division
Central Glass & Ceramic Research Institute
Kolkata 700032, India
E-mail: 1 [email protected], 2 *[email protected],
3
[email protected], 4 [email protected]
Abrasive water jet machining (AWJM) process has potential to cut a wide range of materials, both metallic
and non-metallic. Though, applicability of AWJM on crystalline materials is established, yet no such work
is found on amorphous materials. Borosilicate glass is one of the most regularly used amorphous
engineering materials. Brittleness of this glass puts limitation on its machining by conventional machining
processes. In this article, experiments are conducted on cutting of borosilicate glass by AWJM. Material
removal rate (MRR) and depth of cut (DOC) are measured with different settings of machine parameters –
water pressure, abrasive flow rate, traverse speed and standoff distance. Due to stochastic nature of these
responses and heterogeneous material properties, one of the most advanced generalized learning based
systems, support vector machine (SVM) which could read the underlying unseen effect of input factors on
responses, is applied for developing a unified regression model of responses – MRR and DOC of
borosilicate glass, that can predict both the responses simultaneously. Gaussian radial basis function and insensitive loss function are used as kernel functions and loss function respectively. Multi-objective particle
swarm optimization (MOPSO) is employed to search the optimal combination of internal parameters of
SVM. Model, thus developed, is validated with follow up testing data sets. In addition, scanning electron
microscopic image reveals to some extent, the nature of cut surface and erosion behaviour of amorphous
material qualitatively.
Keywords: Abrasive water jet machining (AWJM); Support vector machine (SVM); Borosilicate glass
Multi Objective Optimization of Cutting Parameters in Micro-milling of Ti-6Al-4V
Alloy
H. Sooraj1*and J. Mathew2
1*
IFFCO Kandla, 370203, [email protected]
2
NIT Calicut, 673601, [email protected]
Micro milling is generally defined as milling of components with end mill sizes in micrometer range (1 to
999 µm). Uncut chip thickness and premature tool wear are the major problems faced during micro-milling.
These difficulties are more pronounced when machining alloys like Ti-6Al-4V. As micro-milling is a tool
based process, any development in the process greatly depends on the advancement in the manufacturing of
micro end mill cutters. A number of coatings like cBN,TiN, TiAlN, TiCN, Diamond, etc. are provided to the
end mills to increase the performance. The effect of tool coating, cutting speed, feed per tooth and axial
depth of cut is studied in terms of surface roughness and total top burr-width. The effect of these factors on
surface roughness and total top burr-width seems to be conflicting. So an optimization of process parameters
is essential for carrying out the milling process efficiently. In this study process parameters (type of tool,
cutting speed, feed per tooth and axial depth of cut) are optimized to improve surface finish and reduce total
top burr-width simultaneously. The experiments are designed based on Taguchi’ s orthogonal array L18.
Key words: Micro-milling, Ti-6Al-4V alloy, optimization, Orthogonal Array, L18.
Investigation of the effects of process parameters on material removal rate & Tool
wear rate during wet & near-dry EDM process
1
P Tripathy1, K P Maity2and B Rajiv3
National Institute of Technology, Rourkela, 769008, Email:[email protected]
2
National Institute of Technology, Rourkela, 769008, Email:[email protected]
3
College of Engineering, Pune, 411005, Email:[email protected]
Electro-discharge machining (EDM) process has achieved a status of being absolutely necessary in the
industry because of its ability to machine any electrically conductive material which is difficult-to-machine
irrespective of its mechanical strength. Near-dry EDM is proved to be most environment-friendly and
having the advantage over problems like higher discharge energy requirement in wet EDM and the
reattachment of debris to the machined surface in dry EDM. In addition to this, the process has also proved
its capabilities in finish operation with low discharge energy considering the higher material removal rate
(MRR) than wet EDM and better surface finish than dry EDM. In this paper, comparison of process
parameters in wet & near-dry EDM drilling on Mild steel material using copper tubular electrode is carried
out. The tool used is a tubular copper electrode. The dielectric used during experimentation is distilled water
for wet EDM process and a combination of distilled water and oxygen at pressure of 2 MPa for near-dry
EDM process. The entire experiments are based on factorial regression. The MRR and tool wear rate (TWR)
are calculated and expressed in the form of generalized equations. Further, the input parameters are
optimized using Linear Programming technique.
Keywords: Near-dry EDM, MRR, , TWR, LPP technique.
Response Surface Modeling of Electric Discharge Machining Process Parameters for
EN 24 Low Alloy Steel.
N. Annamalai1+, V. Sivaramakrishnan2 and N.Baskar3
1+
Department of Mechanical Engineering, Mookambigai College of Engineering, Pudukkottai – 622502,
Tamilnadu, India.E-mail: [email protected]
2
Department of Mechanical Engineering, Roever Engineering College, Perambalur – 621212, Tamilnadu,
India.E-mail: [email protected]
3
Department of Mechanical Engineering, Saranathan College of Engineering, Tiruchirappalli – 620012,
Tamilnadu, India. E-mail: [email protected]
Electric Discharge machining is used to produce complex shapes that would be difficult to produce in
conventional machine tools and also good surface finish can be obtained in EDM. The work material EN24
is machined by using copper as electrode. The EN24 contains nickel, chromium and molybdenum and it is
used in automobile and aircraft transmission components .For this reason, the EN24 is experimentally
investigated with the machining parameters for achieving maximum MRR and minimum electrode wear
rate and surface roughness. The RSM is also used to identify the machining parameter responses on MRR,
EWR and SR. The input parameters are peak current, pulse on time and pulse off time. The experimental
design is done using Box Behnken design of RSM. Regression equations are formulated based on the
experimental results. The effects of input parameters are analyzed on MRR, EWR and SR.
Keywords: EDM, Response surface methodology, Material removal rate, Regression analysis
Fabrication of Disc Shaped Microtool by Electrochemical Micromachining for
Micromachining Applications
V. Rathod1*, B. Doloi2and B. Bhattacharyya3
Production Engineering Department, Jadavpur University, Kolkata, India.
Email:1*[email protected]
2
[email protected]
3
bb13@rediffmailcom
Electrochemical micromachining (EMM) is widely used for micromachining applications due to its various
benefits over other micromachining methods. Microtool is the vital element in EMM, since the features of
the microtool like shape, size and surface finish are directly transferred to the work surfaces affecting its
machining accuracy and surface quality. Disc shaped microtools are useful to improve the machining
accuracy in terms of reduced overcut, taper angle and stray current effects in EMM. Disc microtools
fabricated by different machining techniques needs separate machine setup and includes microtool handling,
increasing the risk of microtool damage. This paper presents the micro machining techniques to fabricate the
disc shaped microtools of different shank diameters, disc diameters and different disc heights with improved
surface quality as required for micromachining applications, from tungsten microrod by EMM. Finally, disc
shaped microtool of disc 175 µm, disc height 70 µm and shank 93 µm was fabricated from tungsten
microrod of 300 µm and used to machine the micro features like straight cylindrical microhole, straight
walled microgroove and 3D micro structures on stainless steel by EMM.
Keyword: Electrochemical micromachining, Disc shape microtool, Shank diameter, Disc diameter, Disc
height.
Optimization of Electrical Discharge Machining Parameters Using Artificial Neural
Network with Different Electrodes
V.Balasubramaniam1*, N.Baskar2and C.Sathiya Narayanan3
1*
Department of Mechanical Engineering, J.J College of Engineering and Technology, Tiruchirappalli, Tamil Nadu,
India, 620 009, Email: [email protected].
2
Department of Mechanical Engineering, Saranathan College of Engineering, Tiruchirappalli, Tamil Nadu, India, 620
012, Email: [email protected].
3
Department of Production Engineering, National Institute of Technology, Tiruchirappalli, Tamil Nadu, India, 620
015, Email: [email protected]
Electrical Discharge Machining (EDM) is a time consuming process and the operating cost is high.
Optimum machining conditions reduces the machining time in the EDM process and yield better
performances. Electrode material is also having their significance in the performances. In this paper a work
has been carried out with different electrode materials namely copper, brass and tungsten while EDM of AlSiCp Metal Matrix Composite. Material Removal Rate (MRR), Electrode Wear Rate (EWR) and Circularity
(CIR) are considered as the performance measures. Artificial Neural Network is used for optimization of the
machining parameters such as current, pulse on time and flushing pressure. Investigations indicate that the
current is the most significant parameter. Among the three electrodes copper yields better performances.
Machining time is reduced with better performances.
Key words: EDM, MRR, ANN, Circularity
Optimization of the quality and productivity characteristics of AISI P20 tool steel in
EDM process using PCA-based grey relation analysis
S. Dewangan1*, C. K. Biswas2and S. Gangopadhyay3
Department of Mechanical Engineering, N.I.T. Rourkela, Odisha- 769008, India
2
Department of Mechanical Engineering, UniversitiTeknologiPetronas, Ipoh, Malaysia
1*
2
3
1*, 3
In the recent years, there is a growing demand for new manufacturing technologies to meet the productivity
and quality requirement in the industries. Electro discharge machining (EDM) is one of the most versatile
machining processes due to its capability to generate complex shapes particularly on difficult-to-cut
materials. In the present work, L18 OA based on Taguchi experimental design is used to study the effect of
various EDM process parameters like discharge current (Ip), pulse on time (Ton), duty cycle (Tau) and
polarity (straight and reverse) on material removal rate (MRR), surface roughness (SR) and surface crack
density (SCD). A hybrid methodology consisting of principal component analysis (PCA) combined with
grey relation analysis (GRA) has been adopted in order to simultaneously optimize various EDM parameters
with an aim to achieve reasonably low value of SCD and SR and high value of MRR during EDM of AISI
P20 tool steel using brass electrode.
Keyword: Grey relation analysis, Principal component analysis, Electro discharge machining, Multiobjective optimization.
Paper #AIMTDR-O0174 (Oral Presentation)
Experimental Study of Material Removal Rate, Surface Roughness &
Microstructure in Electrochemical Machining of Inconel 825
A. Mohanty1*, Gangadharudu Talla2, S. Dewangan3and S. Gangopadhyay4
1
Department of Mechanical Engineering, National Institute of Technology, Rourkela, [email protected]
2
3
4
Department of Mechanical Engineering, National Institute of Technology, Rourkela, Odisha-769008
[email protected]
Electrochemical machining (ECM) is one of the widely used non-traditional machining processes especially
used for producing intricate or complex geometry on difficult-to-machine materials. Owing to this capability
of machining any electrically conductive materials irrespective of its hardness, this process can be utilized to
machine Ni-based super alloys which are termed as difficult-to-cut materials due its properties such as low
thermal conductivity, high strain hardening tendency and high mechanical properties which although makes
it very useful for high temperature applications but on the other hand it possess a significant challenge to
machine by any conventional machine. The present study investigates the effect of process parameters such
as electrolytic concentration, voltage and feed rate on performance characteristics such as material removal
rate (MRR) and surface roughness (SR) when ECM of Inconel 825 by copper tool in an aqueous solution
NaCl solution. ANOVA were employed to investigate the influence of process parameters on performance
characteristics during machining. It was observed that MRR increased with increase in voltage whereas SR
decreased. Voltage was found to be significantly affecting the MRR and SR. An attempt has also been made
to study the microstructure of machined surface at different conditions and to correlate it with multiple
performance characteristics.
Keywords: Inconel 825, Microstructure, Taguchi, ANOVA
Nano-Groove Generation by Diamond Turn Machining and Chemical Processing
Prabhat Ranjan1*, Anuj Sharma2, R. Balasubramaniam3 and V.K. Suri4
Precision Engineering Division, Bhabha Atomic Research Centre, Mumbai-400085
1*
Email: [email protected]; 2Email: [email protected];
3
Email: [email protected]; 4Email: [email protected]
Nano features like texturing, channels, grooves, wells, pillars, etc., have very wide range ofapplications in
many areas. Different techniques are developed by various researchers to generate these features on various
engineering materials. An attempt is made in this study to generatenano grooves on an aluminium alloy, grade6061 pre-machined by diamond turning process.In this study, the deterministic spiral lay pattern generated on
the surface has been subjected to chemical processing. Of the two developed processes, one has resulted in
smoothening of the surface and another has resulted in generating nano grooves along the spiral pattern on the
flat surface of the subtract. The experimental results of this study are presented and discussed in this paper. The
developed process has potential to fabricate various types of nano features like optics, gratings,micronanostructures, nano-fluidic chips, etc.
Keywords: Nano features, DTM, Surface finish, Chemical treatment, Nano-channel
A Neuro-Fuzzy Approach for Optimization of Multiple Responses in Taper Cutting
Using Wire Electrical Discharge Machining
B. B. Nayak1*and S. S. Mahapatra2
[email protected], [email protected]
1,2
Department of Mechanical Engineering, National Institute of Technology, Rourkela
1
Wire electrical discharge machining (WEDM) is extensively used non-traditional machining process for
machining of hard and difficult to machine materials when precision is of prime importance. Tapering
operation in WEDM is a unique ability of this process which can generate curved surfaces on work piece.
During taper cutting operation in wire-EDM, the wire is subjected to deformation resulting deviations in the
inclination angle of machined parts. Hence, the machined part loses its precision.Therefore, simultaneously
improving more than one performance measures during taper cutting becomes a challenging task. In this
work, experiments have been conducted to study the influence of six input parameter on angular error,
surface roughness (SR) and cutting speed (CS) using Taguchi’ s experimental design method. A neuro-fuzzy
approach is proposed to convert the multiple responses into a single equivalent response known as Multi
Performance Characteristic Index (MPCI). The effect of parameters on MPCI has been studied. Analysis of
Variance (ANOVA) is conducted to determine the statistical significance of process parameters during taper
cutting in WEDM process. A confirmatory test has been carried out to verify the optimal setting so
obtained. The results from the confirmation runs indicate that the determined optimal combination of
machining parameters can simultaneously improve multiple performance measures in tapering cutting.
Keywords:Neuro-fuzzy System, MPCI, Taper cutting, ANOVA
Experimental Investigations for Al2o3 Ceramic Micro Machining Using Ecdm Process
Anjesh H Sahasrabudhe1* and B. B. Ahuja2
Production EngineeringDepartment,College of Engineering, Pune - 411005,
Email id: [email protected]
2
Production EngineeringDepartment,College of Engineering, Pune - 411005,
Email id: [email protected]
1
The machining of nonconductive ceramic like aluminium oxide (Al2O3) is a major challenge for user
industries. Electrochemical discharge machining (ECDM) is an alternative to process difficult to machine
materials like aluminium oxide, glass etc. This research focuses on the development of gravity feed ECDM
set up for machining of nonconductive Al2O3 ceramic. This specially designed set up consists of fixture to
hold the work piece and the tool holder to guide the tool used for experimentation. The auxiliary electrode
has been kept at bottom side of the fixture. The fresh electrolyte is supplied for the ECDM process by using
pair of pumps, one for delivering fresh electrolyte at machining point and another for the removal of
electrolyte from the machining point. The feasibility of the fabricated setup has been experimentally
verified. Experiments are carried out by stainless steel and copper tool to analyze the effect of various
process factors of ECDM on material removal rate (MRR) and diametric over cut (DOC). From
experimental results and analysis of variance, it is evident that voltage and concentration of electrolyte are
the significant factors affecting the responses. Signal to Noise ratio (S/N) is evaluated to determine the
relative contributions of vital machining parameters. The optimization technique called “ Rotating Vector
Operator Process” (ROVOP) is used to determine the optimal parametric combination. It is used to
determine behavior of the curve between two extreme values of the selected variables.
Keywords: ECDM, Signal to Noise Ratio, ROVOP.
An Expert System for Non-traditional Machining Process Selection
Kanika Prasad1*and Shankar Chakraborty2
Department of Production Engineering, Jadavpur University
Kolkata - 700 032, West Bengal, India, E-Mail: [email protected]
2
Kolkata - 700 032, West Bengal, India, E-Mail: [email protected]
1*
A rapid increase in the use of harder and difficult-to-machine metals and alloys has led to the development
of non-traditional machining (NTM) processes. In NTM processes, material removal takes place employing
mechanical, thermal, electrical, chemical energy or combinations of these energies, without the use of a
sharp cutting tool. These advanced machining processes are used to generate intricate and accurate shapes in
materials, like titanium, fiber-reinforced composites, ceramics, refractories and other difficult-to-machine
alloys having higher strength, hardness, toughness and other diverse material properties. As various NTM
processes with different capabilities and specifications are available today for a wide range of applications,
there is a need for selecting a suitable NTM process for a particular application for effective utilization of its
machining capabilities. The past researches reported on the selection of NTM processes using expert
systems, mathematical approaches and multi-criteria decision-making models. Most of those methods do not
provide due importance on the customers’ requirements. Quality function deployment (QFD) is a customerfocused decision-making tool to integrate needs of the customers with process capabilities. In this paper, a
QFD-based expert system in Visual BASIC 6.0 is developed to consider customers’ requirements in NTM
process selection decision. Two illustrative examples are provided to demonstrate the applicability of the
developed expert system for NTM process selection.
Keywords: Non-traditional machining process, Quality function deployment, Expert system
Experimental Investigation of Ultrasonic Machining On Alumina Bio-Ceramic for
Stepped Hole Fabrication
S.Das1*, B. Doloi2 and B. Bhattacharyya3
Production Engineering Department, Jadavpur University, Kolkata, India
2
3
Ultrasonic machining (USM) has immense potential for machining hard and brittle materials such as
ceramics, bio-ceramics and glasses, etc. irrespective of electrical conductivity of the workpiece material.
Alumina (Al2O3) is very hard and brittle bio-ceramic material and highly biocompatible. It is very difficult
to machine by any conventional machining process. For this reason ultrasonic machining is applied for these
bio-ceramic materials. Stepped hole generation on the alumina implant is required for proper fitting in our
chewing gum. This paper presents the study on the influences of ultrasonic machining process parameters
such as abrasive grain size, power rating and tool feed rate on generated stepped hole profile. The material
removal rate and accuracy of the job profile such as over cut of larger diameter (OLD) hole and over cut of
smaller diameter (OSD) of the stepped hole profile have been studied. Based on experimental results, the
influences of abrasive grain size, slurry concentration and power rating have been studied through graphical
representation of the results.The experimental investigations carried out for determining the influence of
USM process parameters will provide effective guideline to select parametric settings for achieving
maximum material removal rate and desired job profile accuracy on stepped hole drilling operation on
alumina.
Keywords: Ultrasonic Machining; Alumina, Material removal rate, Over cut of larger diameter hole, Over
cut of smaller diameter hole and stepped hole
1*
Artificial Neural Network Modeling for Prediction of performance in Abrasive Jet
Drilling Process for Glass material
1,2,3,4
J.R. Samani1, H.S.Beravala2*, P.B. Jadav3 and C.J. Dusra4
Department of Production Engineering Birla VishvakarmaMahavidyalaya Engineering College,
VallabhVidyanagar, 388120, [email protected]
The prediction of process performance is important to set the control parameters for achieving the goals of
production. Abrasive jet machining is a suitable process for machining of brittle materials like Glass,
ceramic etc. Glass is a widely used engineering material in optical and other applications. For this purpose,
full factorial design of experiment was carried out to obtain data regarding the effect of process parameters
on abrasive jet drilling process for glass as work material. Attempt of this paper is to development of
predictive models for input parameters which are air pressure, stand of distance and abrasive grit size and its
effect on responses such as which are material removal rate, radial overcut and taper. Various ANN
architecture was developed their accuracies in prediction are determine by calculating various errors and
variance between actual experiment result and predicted results obtain by ANN models using 80:20 rule.
Major conclusion of this paper is, artificial neural network model is used to capture relationship between
input and output parameters so it works as a modeling tool to predict the performance of the process.
Keywords: Abrasive jet drilling, Glass, Artificial Neural Network (ANN)
Experimental Investigations into Micro-Drilling Using Air Assisted Jet Electrochemical
Machining
Harsha Goel1 and Pulak M Pandey2*,
IIT Delhi, 110016, E-Mail: [email protected]
2*
IIT Delhi, 110016, E-mail: [email protected]
1
The work describes the development of the process to drill the micro-hole with jet-electrochemical
machining (Jet-ECM) method assisted with air. The experimental set up has been fabricated and the effects
of air pressure along with the other process parameters has been investigated experimentally on the process
responses namely MRR and hole taper. Use of air along with the jet-improves the machining conditions
during Jet-ECM. It has been observed that the flow of air pushes away the accumulated electrolyte from the
area of impingement of the jet over the work-piece. Due to this, thin film flow of electrolyte in the
machining area is observed which is necessary for jet-electrochemical machining. This reduces the chances
of sparking occurring at the electrolyte jet and work-piece interface due to accumulation of electrolyte on
work-piece surface. The coaxial air flow tends to localize the work-piece dissolution which results into more
accurate holes closer to the nozzle or tool diameter. No change in MRR is observed with the assisted air
supply but hole accuracy improves.
Keywords: Jet-ECM, Assisted Air, MRR, Taper.
Investigation into Electrochemical Micromachining Process for Fabricating 3D Fine
Patterns in Air Lubricated Bearing
Debnath S.1*, Mahata S.1, Bandopadhyay K.2and Bhattacharyya B.1
1*, 2, 3
Production Engineering Department, Jadavpur University, Kolkata, India,
2
Precision Engineering Division, Barc Mumbai, India
Electrochemical Micromachining (EMM) is an electrochemical material removal process which has a large
potential due to its several opportunities it offers in the fabrication of micro shapes and may be used as one
of the best machining process to build up complex forms in micrometer ranges applicable in various
demanding and sophisticated areas. But, in spite of this, generating 3D micro structures, in micrometer
levels is still very difficult and a few number of research works have been carried out on it. Therefore, the
present work is directed towards generating 3D fine patterns of an air lubricated bearing with
Electrochemical Micromachining where attempts has been made to investigate the effect of influencing
process parameters on depth and roughness values of the generated micro patterns and from the conducted
experiments, 5V, 8 MHz frequency, 0.1 M H2SO4 with 30% and 50% duty ratio produced the best
machining with noticeable values of depth which are 111 µm and 148 µm and moderate values of roughness
which are 0.387 µm and 0.267 µm respectively.
Keywords: Electrochemical micromachining (EMM), 3D fine pattern, Surface parameters, Depth
measurement.
Experimental Investigation into Generation of Micro Hole on Titanium By
Electrochemical Micromachining
1*
Sandip S. Anasane and 2B. Bhattacharyya
Production Engineering Department, Jadavpur University, Kolkata, India-700032
1
*E-mail:[email protected]
2
The machining of titanium in micro domain is a topic of great research interest. Machining of titanium by
conventional as well as non conventional methods is always appeared as challenge due to its unique high
strength to weight ratio and their exceptional corrosion resistance.Electrochemical micromachining (EMM)
technique has been demonstrated successfully in this work to generate the micro feature i.e. micro holes.
The developed experimental set up of EMM was utilized for fabrication of through micro holes on pure
commercial titanium to investigate the effect of different machining parameters i.e. machining voltage, duty
cycle, frequency and tool feed rate on radial overcut of micro hole. The micro holes were machined by
conducting set of experiments designed according to the Taguchi quality design concept. The most
significant parameters, which influences the radial overcut of micro hole were also determined. Electrolyte
of fresh sodium bromide with ethylene glycol was utilized. A tool of 200 m diameter copper rod was used
for machining.
Keywords: Electrochemical micromachining, Titanium, Micro feature, Machining voltage
Computational Analysis for Mixing of Fluids Flowing through Micro-Channels of
Different Geometries
Sankha Shuvra Das1*, Binay Kumar Patawari2, P.K. Patowari3 and S. Halder4
1*,3,4
Department ofMechanical Engineering, NIT Silchar, Assam, 788010,
2
Department ofMechanical Engineering, ISM Dhanbad, Jharkhand, 826004
Emails: 1*[email protected], [email protected], [email protected],
4
[email protected]
Rapid and uniform mixing is a key consideration in the design and development of micro-mixers. In micro
scale, as the flow is laminar, mixing is dominated by molecular diffusion only. Hence, the presence of
confluence or bends in the path of fluid flow causes rapid and uniform mixing of fluids. This paper presents
a computational study of mixing of fluid in the micro-channel and investigates the mixing efficiency in
straight, square wave and in three dimensional (3D) serpentine micro-channels. For all the geometries the
basic dimensions as 400µm of width, 200µm of depth, 266.67 µm of hydraulic diameter and 11.5 mm of
linear length are considered. The 3D models for all the geometries are developed using CATIA v6 and
simulation is done using COMSOL Multiphysics software. The simulation is done for normal inflow
velocity of 0.0002 m/s, 0.0004 m/s and 0.0006 m/s with Reynolds’ number (Re) of0.053, 0.106 and 0.160
respectively. To characterize the mixing efficiency, properties of water such as viscosity and density are
considered as the fluid properties and fluid concentration of 0 mol/m3 and 50 mol/m3 are used through two
different inlets respectively. The simulation results showed that at Re = 0.106, 3D serpentine micro-channel
gives higher and uniform mixing than others. The analysis indicated that mixing efficiency is strongly
dependent on the geometry of the micro-channel. In 3D serpentine micro-channel due to its change of plane,
occurrence of fluid stirring and swirling vortexes are more, which enhances diffusion gradients resulting
increase in mixing efficiency. The pressure drop during the fluid is also found out for straight, square wave
and three dimensional serpentine micro-channels. The velocity vector plots showed the velocity profile and
path of fluid flow throughout the length of channel.
Keywords: Micro-channel, Micro-mixing, Micro-fluidics.
Modeling of Wire Electrical Discharge Machining of AISI D3 Steel using Response
Surface Methodology
1
Brajesh Lodhi1 and Sanjay Agarwal2*
Bundelkhand Institute of Engineering & Technology, Jhansi, U.P.284128, INDIA
Bundelkhand Institute of Engineering & Technology, Jhansi, U.P.284128, INDIA
2*
2*
This paper present set of parameters that exhibit flexibility, frequent and miscellaneous collection based on
experience and technology. It suggests an experimental analysis to establish the parameters location during
the machining of AISI D3 steel. Response Surface Methodology (RSM), a powerful tool for experimental
design, is used to optimize the CNC-wire cut EDM parameters. A central composite rotatable design
(CCRD) has been used to develop the mathematical models involving input parameters and responses. The
input parameters like pulse-on time, pulse-off time, peak current and wire feed have been taken for
experimentation. The responses to be measured are MRR and surface roughness. Results indicates that pulse
on time and pulse off time are directly proportional to the surface roughness where as peak current and wire
feed is inversely proportional to the surface roughness. It is also observed that at higher value of wire feed
and lower value of pulse on time, the MRR is maximum. At the same time, for the higher value of pulse on
time and for the lower values the wire feed, MRR is lower. Further the values predicted by the developed
mathematical models yielded results which agree reasonably well with the experimental results.
Performance of Monopole Concentrator during Microwave Drilling of Perspex
1,2,3
Nitin Kumar Lautre1*, Apurbba Kumar Sharma2, Pradeep Kumar3and Shantanu Das4
Department of Mechanical and Industrial Engineering, Indian Institute of Technology Roorkee, Roorkee,
Uttarakhand, India - 247667.
4
Reactor and Control Division, Bhabha Atomic Research Center, Mumbai, Maharashtra, India.
E - Mail: 1*[email protected], [email protected], [email protected],
4
[email protected]
The applications of microwaves in engineering has been fast expanding, one such area is micromachining
and micro-fabrication. A series of experiment with different types of concentrator (steel, copper and
nichrome) was carried out. Different machining conditions like variable power, location and movement
were considered. The drilled hole shows development of three different heat affected zones (HAZs). The
performance of the process was evaluated in term of the residue diameter, HAZ diameter and the hole
diameter. Energy Dispersive Spectroscopy (EDS) and field emission scanning electron microscope
(FESEM) were used to assess the zone and damage of the monopole concentrator used as drilling tool. The
drill bit damage in its length was controlled with careful selection of process parameters. An optimum
processing condition was determined experimentally, for minimum residue generation, minimum HAZ and
minimum oversize of drilled holes. The depth of through hole in perspex material was maintained constant
at 2 mm.
Keywords: Microwave, Drilling, Concentrator, HAZ, EDS, FESEM.
A study on wire breakage and parametric efficiency of the wire electro chemical
discharge machining process
1
Amrinder Singh, 2*C. S. Jawalkarand 3Rahul Vaishya and 4Apurbba Kumar Sharma
Department of Production Engineering,
PEC University of Technology,
Chandigarh, India- 160012.
1
[email protected], 2*[email protected], [email protected],
4
[email protected]
The Wire Electrochemical Discharge Machining (WECDM) is a non- conventional process, typically used
in cutting brittle and hard non-conductive materials. The WECDM is relatively new research area compared
to its principle process- ‘Electro Chemical Discharge Machining (ECDM). In the current investigation, the
wire breakage problem, commonly encountered while machining fine slots has been addressed. The aim was
to reduce the wire breakage through optimum parametric settings, to understand the wire breaking voltages
at different electrolytic concentrations along with its effect on the MRR, length of cut and width of cut. In
this study, zinc diffused brass wire of fine diameter (0.20 mm) was used in experiments and the results of
the same are being reported in the paper. The response parameters used in the investigation were MRR and
width of cut; while the process parameters were workpiece feed rate, electrolyte concentrations and applied
voltage.
Keywords: WECDM, Material removal, Electrolyte concentration, Wire breakage
Studies on Tool Wear Characteristics in Micro Electro Discharge Slotting Process (µEDS)
Harshit Dave1*, Vishal Mathai2, Mukul Mayanak3, Harit Raval4and Keyur Desai5
Department of Mechanical Engineering, S. V. National Institute of Technology, Surat, Gujarat,
India,395007
Email: 1*[email protected], [email protected], [email protected],
4
1*,2,3,4,5
Micro Electro Discharge Machining and its process variants have a wide range of acceptance for the
generation of various types of micro features and micro components despite its limitations like tool
electrode wear. This paper discusses a technique called Micro Electro Discharge Slotting (µ-EDS) which
can be used for the generation of micro slots; a feature characteristic which have wide range of applications.
An experimental investigation has been carried out to understand the effect of various electrical parameters
like Current, Gap voltage, Pulse ON time and Pulse OFF time and non-electrical parameters like scanning
speed of the tool and aspect ratio of the micro feature generated on Tool Wear Rate during the machining of
Al1100 using Tungsten electrode. Taguchi methodology has been used to design the experiments. Analysis
of Variance results suggest that scanning speed of the tool electrode have the most significant effect on Tool
wear rate during µ-EDS with a percentage contribution of 37.72%. Further, aspect ratio of the feature, pulse
ON time and current are also observed to have significant effects on the response in 95% confidence
interval.
Keywords: Micro EDM, Slotting, Tool Wear, Scanning
Electro Discharge Machining of Aisi 304 Using Solid and Bundled Electrodes
Harshit K. Dave1*, Sudhanshu Kumar2, Nipul C. Rana3and Harit K. Raval4
1,2,3,4
Department of Mechanical Engineering, S.V.N.I.T, Surat, Gujarat-395007
*1
[email protected], [email protected], [email protected], [email protected]
This paper presents the investigation on generation of square shape cavities with solid and bundled tool
electrodes. The workpiece and tools material are AISI 304 and electrolytic copper respectively. Effect of
peak current and pulse on time has been observed on machining performance in terms of material removal
rate and tool wear rate. Three different levels of peak current and five levels of pulse on time have been
selected for investigation. To remove the un-machined pinned shape structure of workpiece, 1mm orbital
radius has been given to both the electrodes. Experiments have been designed using fractional factorial
design. The experimental results indicate that solid tool yields 45% more material removal rate than bundled
tool electrode and TWR for both tool is decreasing with pulse on time.
Keywords: Orbit radius, Solid tool, Bundled tool, Factorial desig
Modeling of Wire EDM slicing process for Silicon
Kamlesh Joshi1, Gaurav Sharma2, Ganesh Dongre3 and Suhas S. Joshi4*
Department of Mechanical Engineering, Indian Institute of Technology Bombay, Mumbai, 400076
E-Mail: [email protected], [email protected], [email protected],
4*
[email protected]
1,2,3,4
Wire-EDM is an emerging technology for Si ingot slicing with minimum kerf- loss and crack-free surface.
In this work, a mathematical model has been developed using dielectric-ingot material properties, heat
transfer equations and steady state heat source characteristics to predict temperature profile, melt radius and
erosion rate for the ingot and its dependence on voltage, current, wire diameter and ‘pulse on-time’ have
been considered. Modeling of plasma for different phases like ignition phase, heating phase and removal
phase has been done and the concept of mean free path (MFP) of electron is used to obtain the temperature
profile at plasma-anode interface. The erosion rate predicted using the model has been found to be greater
than experimental values. However, with a consideration of ‘plasma flushing efficiency’ , corrected erosion
rate matched well with experimental values.
Keywords:Kerf-loss, Mean free path, Melt radius, Erosion rate
Experiments and Simulation of Three Dimensional Micro EDM with Single and
Multiple Discharges
Alwin Varghese1*, Kuriachen B.2, Satyananda Panda3 and J. Mathew4
1*
MED, NIT Calicut, 673601, [email protected]
2
3
MAT, NIT Calicut, 673601, [email protected]
4
In this paper, simulation results for both single spark and multi-spark micro electric discharge machining
(µEDM) process for RC circuit based micro EDM is presented. Various factors like latent heat of fusion,
latent heat of vaporization and temperature dependent properties of material are taken into consideration in
the model. Spark radius models developed by many researchers are studied and compared in this work. The
distribution of temperature resulting from the spark machining process of a 3D work-piece is modeled based
on the finite volume method. The crater dimensions are determined with the help of temperature
distribution in the workpiece. The numerical results for single spark phenomenon are validated by the
experimental results performed on Micromachining Center, DT-110. Tungsten Carbide is used as the tool
and Ti6Al4V as the work-piece for conducting the experiments. The crater diameter is measured using
scanning electron microscope (SEM) and it is observed that the experimental values are close to the
simulations results for single spark EDM process. Moreover multi-spark analysis is done and the effect of
spark on time and spark off time is studied.
Keywords: Finite volume method, Micro EDM, Multispark, RC Circuit.
Numerical Modeling and Multi-Objective Optimization of Micro-Wire EDM Process
Dinesh Babu P.1*, Deepak G Dilip2, Somashekhar K.P.3, Allesu K.4 and J. Mathew5
1*
NIT Calicut, 673601, E-mail: [email protected]
2
NIT Calicut, Pin-673601 E-mail: [email protected]
3
DTE, Bangalore, E-mail: [email protected]
4
NIT Calicut, 673601, E-Mail: [email protected]
5
MED, NIT Calicut, 673601, E-mail: [email protected]
With more and more demands of complex micro parts in the field of MEMS, biomedical devices, aerospace,
nuclear, electronics, optics, communication, etc., the manufacture of micro products has been a focus in the
manufacturing industry. Micro-Wire Electrical Discharge Machining (µ-WEDM) is emerging as one of the
popular machining process for precision manufacturing of complex micro parts rapidly and accurately on
hard-to machine materials that are electrically conductive. Determining the optimum machining parameter
combination of µ-WEDM in industries mainly rely on the operator’ s skill despite extensive researches. In
this paper an attempt is made to numerically model the spark erosion rate of µ-WEDM process using finite
difference method (FDM) considering circular moving heat source. The temperature distribution along the
micro-wire length is used to find the material removal rate for different voltage-capacitance combinations.
Also the effect of process parameters in machining Inconel-718 is investigated and optimized using GreyTaguchi analysis. The Taguchi method based L18 orthogonal array experimental design is used to determine
the S/N ratios to indicate the process parameters (voltage, capacitance, feed rate, wire tension and wire feed
velocity) which affect the machining performances (MRR and surface roughness) significantly. ANOVA
(Analysis of variance) was employed to identify the level of importance of machining parameters on the
responses. The experiments were repeated three times and the average value is taken.
Keywords:µ-WEDM, Taguchi Method, Grey Relational Analysis
Modelling Of Micro Electric Discharge Machining Using FEM
Mithun S. Nair1*,Kuriachen B.2, R. Vijayakumar3and J. Mathew4
1*
2
3
4
Micro EDM, a nonconventional machining process is widely used in the field of high aspect ratio machining
in micro scale. It is an electro-thermal material removal process, in which there is no physical contact
between tool and workpiece. In micro-EDM, crater formation is due to intense heat generated between the
workpiece and tool electrode. Modeling of micro EDM will give the idea of material removal and
temperature distribution. In previous work, finite element modelling of micro EDM was done using
ANSYS. Temperature distribution and crater formation was studied. In this work, thermal modeling of
micro EDM is carried out using FEM. A numerical simulation of single spark in micro EDM process has
been carried out considering the 2D axi-symmetric process continuum and analysis is based on Gaussian
distribution of heat flux. Themodel was developed using MATLAB and with this developed code the
temperature distribution of micro EDM was studied. The developed single discharge model makes use of
several important aspects such as properties of specific heat, thermal conductivity, percentage distribution of
heat among tool, workpiece and dielectric fluid, and the material ejection efficiency, etc. Ti-6Al-4V was
considered as the workpiece. It is well known for its high strength to weight ratio, which has tremendous
application in automobile, nuclear, biomedical and aerospace. In the developed code, the process parameters
have been considered based on the available machine. The model is compared with previous ANSYS work.
Finally, for further validation, single discharge experiment with RC pulse generator was performed using
titanium alloy and tungsten carbide as the workpiece and tool respectively.
Keywords: micro EDM, Ti-6Al-4V, Modeling, MATLAB
Experimental and Finite Element Based Investigations on Powder Mixed MicroElectrical Discharge Machining of Ti-6Al-4V Alloy
Vipin, V.1*, Kuriachen B.2, Manu, R.3 and J. Mathew 4
1*
MED NIT Calicut, 673601, [email protected]
2
3
4
MED, Dean NIT Calicut, 673601, [email protected]
Micro-Electrical Discharge Machining is a non-conventional machining process that can be used effectively
for the fabrication of micro components. It can be used for machining any type of materials which are
electrically conductive. The main drawbacks of the Micro-Electrical Discharge Machining are the
comparatively poor surface quality and low machining efficiency. In Micro-Electrical Discharge Machining
the properties of dielectric plays an important role. Therefore the performance of Micro-EDM process can
be improved by adding suitable external powder to the dielectric. This paper present an axisymmetric twodimensional model for powder mixed Micro-Electrical Discharge Machining using the finite element
method (FEM). The model has taken into account several important aspects such as temperature sensitive
material properties, shape and size of heat source (Gaussian heat distribution), powder concentration,
percentage distribution of heat among tool, workpiece and dielectric fluid, etc. to predict the material
removal mechanism in PMµEDM process. The model calculated the temperature distribution in the
workpiece material using ANSYS (version 14) software and then material removal rate was estimated from
the temperature profiles. The effect of various process parameters on temperature distributions along the
radius and depth of the workpiece has been studied. The model has been validated by comparing the
theoretical MRR with the experimental results obtained from the setup developed in the laboratory.
Keywords: Powder mixed micro-EDM, ANSYS14, FEM, Gaussian heat distribution.
Experimental Study on Varying Electromagnetic Field Assisted
Die Sinking EDM
Vignesh S. Naidu1, Vipindas K.2, R. Manu3and Jose Mathew4
MED NIT Calicut, Kerala-673601 E-mail: [email protected]
2
MED, NIT Calicut, Kerala-673601 E-Mail: [email protected]
3
MED NIT Calicut, Kerala-673601, E-mail: [email protected]
4
MED, NIT Calicut, Kerala-673601, E-mail: [email protected]
1
The experimental study mainly focuses to investigate the effect on EDM process performed using
electromagnetic magnetic field setup. Maintaining an optimum machining gap is of more concern for
smooth functioning of EDM process, also the process has direct influence with plasma channel and debris
expulsion. Thus ionizing the plasma channel and expelling the debris from the machining gap will improve
the performance measures and surface integrity. In the experiments a copper tool was used to machine a Ti6Al-4V workpiece. Experiments were done using parameters as Current (I), Pulse on time (TON), Pulse off
time (TOFF) and Magnetic field strength (Mf) in EDM process. All parameters were varied in three levels
and system responses measured were material removal rate (MRR) and surface roughness (Ra). A full
factorial design was used to carry out the experiment. The obtained results were analyzed and a model
equation was obtained for predicting MRR and surface roughness respectively. The significance of each
parameter was analyzed by Analysis Of Variance (ANOVA), also the best process parameters for
maximizing MRR and minimizing surface roughness (Ra) was found, later results were validated.
Key words: EDM, electro-magnetic field assisted, Material removal rate, Surface roughness.
Modeling and Multi-Response Prediction of Micro Edm Drilling on Inconel 718
Kuriachen B.1*and J. Mathew 2
Research Scholar, NIT Calicut, Pin-673601, E-mail: [email protected]
2
Professor & Dean (R&C), MED, NIT Calicut, Pin- 673601, E-mail: [email protected]
*1
Micro electric discharge machining is an important micro thermal erosion machining process which can
produce high aspect ratio holes in electrically conductive difficult to machine materials irrespective of
hardness. The objective of this study is to investigate the effect of various micro EDM drilling (RC pulse
generators) parameters on machining inconel 718 using tungsten carbide as the tool electrode. Response
Surface Methodology (RSM) and artificial Neural Network (ANN) with back propagation algorithm have
been used for conducting experiments and modeling respectively. The experiments were conducted
according to Box Behnken design matrix. Gap voltage (A), Capacitance (B), Feed rate (C), and Dielectric
flow rate (D) were considered as the process parameters for experimentation. The performance measures
were material removal rate (MRR), tool wear ratio (TWR), and overcut (OC). ANN models have been
developed with varying number of neurons in the hidden layer from 5 to 15. It was found that one hidden
layer with 9 neurons predicted the best results. Hence, a feed forward back propagation neural network of 49-3 was adapted to micro EDM drilling process. Based on regression analysis of experimental data,
mathematical models were developed. The predicted values were compared with actual experimental results
and the predicted values were almost equal to the expected with very less error.
Keywords: Micro EDM drilling, Inconel 718, RSM, ANN
Spark Radius Modelling of Micro Electric Discharge Machining of Ti-6al-4v
Kuriachen B.1*and J. Mathew 2
Research Scholar, NIT Calicut, Pin-673601, E-mail: [email protected]
2
Professor & Dean (R&C), MED, NIT Calicut, Pin- 673601, E-mail: [email protected]
1
Micro electric discharge machining is an important micro thermal erosion machining process which can
produce high aspect ratio holes in electrically conductive difficult to machine materials irrespective of
hardness. In this paper, an attempt has been made to model the spark radius of single pulse resistancecapacitance discharge experimentally. Full factorial experiments at three different levels have been used to
conduct the experiments. Capacitance and voltage were identified as the important parameter for RC
discharge circuit. Spark radius was selected as the dependant variable and investigated the effect of
individual and interaction effect of capacitance and voltage. In addition, based on regression analysis of
experimental data, a mathematical model was developed. Finally, the prediction accuracy of the developed
model is compared with validation experiments and found that it model can predict the spark radius with
accuracy not less than 94%.
Keywords: Micro EDM, Ti-6Al-4V, Single spark, RC discharge circuit, Mathematical model, Spark radius.
A Study on Effect of EDM Process Parameters on AISI 304L Stainless Steel
D. K. Ojha1*, S. Panda2 and D.Mishra3
Department of Production Engineering, Veer Surendra Sai University of Technology, Burla-768018, Email:
[email protected]
2
Departmentof Production Engineering, Veer Surendra Sai University of Technology, Burla-768018, Email:
[email protected]
3
Departmentof Production Engineering, Veer Surendra Sai University of Technology, Burla-768018, Email:
[email protected]
1*
Electro Discharge Machining (EDM) has become an important and cost-effective method of machining
extremely tough and brittle electrically conductive materials. It is widely used in the process of making
moulds, dies, sections of complex geometry and intricate shapes. The work piece material selected for this
study is AISI 304L Stainless steel. In the present work the effect and percentage contribution of various
machining parameters on output parameters is studied using Taguchi’ s method and ANOVA analysis. A
hybrid Taguchi based grey relational analysis is proposed for multi objective optimization of performance
variables i.e. high material removal rate, low tool wear rate, better surface finish with lower dimensional
tolerance. Further a regression analysis can be used for finding the model equations for various performance
parameters. The input parameters considered in this study are dielectric flow rate, discharge current, Pulse on
time (Ton) and Pulse off time (TOff). The tool material used is copper. Analysis of variance is used to study the
significance of process variables on Material Removal Rate (MRR), Tool Wear Rate (TWR), Surface
Roughness (Ra), Dimensional Tolerance (DT). The analysis using Taguchi method reveals that discharge
current significantly affects MRR, Dimensional Tolerance and Ra whereas TWR is mostly affected by flow
rate of the dielectric used. A comparison of the hybrid approach and Taguchi analysis is presented in this
study. The confirmation test supports the result of the proposed hybrid Grey-Taguchi analysis.
Keywords: EDM, ANOVA, AISI 304L Stainless Steel, Grey Relational Analysis, Taguchi method
High Aspect Ratio Micro-features by Electrochemical Micromachining
B. Ghoshal1* and B. Bhattacharyya2
Production Engineering Department, Jadavpur University, India, Kolkata-700032,
Email- [email protected]
2
Production Engineering Department, Jadavpur University, India, Kolkata-700032,
1*
Experimental investigations were carried out to know the effect of vibration of micro tool, frequency of
pulsed voltage, micro tool tip shape and thickness of work piece on high aspect ratio micro-features. This
paper discusses the micro fabrication of high aspect ratio micro-features at the intended location on high
strength stainless steel sheet of very small thickness of 35 µm to high thickness of 900 µm with highest
aspect ratio 5.1 achieved during microchannel generation by electrochemical micromachining (EMM) with
the help of bare micro tool. Vibration of micro tool with very small amplitude of 3 µm improved the
stability of micromachining due to improved flow of electrolyte.
Keywords: High-Aspect-Ratio Micro features, Microchannels, Micro hole
Investigation and Fuzzy Based Modeling of Micro-Edm Process During Machining of
Micro-Hole in D3 Die Steel Material Employing DE-Ionized Water
1*
I. Shivakoti1*, G. Kibria2 and B.B. Pradhan3
Mechanical Engineering Department, Sikkim Manipal Institute of Technology (SMIT), Majhitar, East Sikkim737136, E-Mail: [email protected]
2
Mechanical Engineering Department, Aliah University, Kolkata-700091,
3
Mechanical Engineering Department, Sikkim Manipal Institute of Technology (SMIT), Majhitar, East Sikkim737136, E-Mail: [email protected]
The correct selection of process parameters for manufacturing is one of the most important aspects taken
into consideration in the majority of manufacturing processes and particularly, in process related to EDM.
The machining characteristics are greatly influenced by the nature of dielectric used during micro-EDM.
The present paper investigates the fuzzy logic model for micro-electrical discharge machining process of D3
die steel employing NaNO3 salt mixed de-ionized water as dielectric fluid. Peak current, pulse-on-time and
salt concentration were considered as process parameters. L9 orthogonal array was considered as design of
experiments. Various performance criteria such as material removal rate (MRR), tool wear rate (TWR),
overcut and taper of micro-hole during machining of D3 die steel were measured at various parametric
combinations of process parameters. The MATLAB logic tool box is used for modeling the process.
Moreover, the regression model has been developed using the toolbox. The experimental, fuzzy predicted
and regression predicted results has been compared using various graphical plots and the results were
analyzed.
Keywords: Micro-electrical discharge machining, Fuzzy logic, D3 die steel, Dielectric fluid
Electric discharge machinability studies on D0403 and D0376 alloy steels
Santosh. S1*, Rajkumar. K2, Raghuraman. S3, Panneerselvam.T4 and Thiruppathi. K5
Department Mechanical Engineering, SSN college of Engineering, Kalavakkam,TamilNadu, India 603110, Email: [email protected]
2
Department Mechanical Engineering, SSN college of Engineering, Kalavakkam, TamilNadu, India 603110, Email: [email protected]
1*
3
School of Mechanical Engineering, SASTRA University, Thanjavur, TamilNadu, India - 613 401
4
5
EDM is an efficient machining process for forming a high aspect ratio hole in higher hardness materials
with various advantages resulting from its characteristics of non-contact and thermal process. A series of
blind holes of 10 mm diameter with depth of 3 mm were produced on D0403 alloy and D0376 alloy by
EDM process using a copper electrode for different combination of process parameters. Material removal
rate (MRR) and tool wear rate (TWR) are reported as performance factors of the machining process. The
experiments were conducted based on varying the process parameters such as pulse on time, pulse off time
and current which can affect the machining process to obtain the required quality characteristics. The
surface roughness values for hole are reported here for quality performance factor. The obtained results are
compared with SG iron with same machining parameters. The results show that material removal rate is a
non linear function of pulse on and off time ratio.
Keywords: EDM, MRR, TWR, Taguchi
Investigations on Grinding of Inconel 718 Using Newly
Developed Graphene Nanoplatelets Impregnated Grinding Wheels
R.Bhanu Pavan1*, G.Bhanu Kiran2, R.R. Srikant3 and A.Venu Gopal4
1*
GITAM University, Visakhapatnam, 530045,
*Email: [email protected]
2
GITAM University, Visakhapatnam, 530045, [email protected]
3
GITAM University, Visakhapatnam, 530045,[email protected]
4
National Institute of Technology, Warangal, 506004, [email protected]
High fatigue endurance upto 7000C and ability to retain chemical and mechanical properties at elevated
temperatures makes Inconel 718 more attractive over titanium alloys especially in applications where high
temperatures are involved. But high hardness, high hot strength and low thermal conductivity makes it
‘difficult to machine’ material. High cutting forces and temperatures generated during grinding of inconel
718 will lead to poor surface quality and shortens grinding wheel life. Application of conventional cutting
fluids in the grinding zone results in further increase of temperature and manufacturing costs. In order to
overcome these difficulties, Nano Graphene impregnated resin bonded grinding wheels are newly developed
and investigations on grinding of Inconel 718 with these newly developed grinding wheels are presented in
this paper.Grinding wheels impregnated with varying weight fractions (0.25, 0.5, 1, 2 & 4) of Graphene
Nano Platelets are fabricated and different aspects of grinding performance (i.e. cutting forcers, grinding
temperatures, surface finish, grinding wheel wear ratio etc) are evaluated and compared with conventional
grinding wheels. New grinding wheels found to be more beneficial over conventional grinding wheels as
they resulted in improvement of surface finish, wheel life and decrease in cutting forces and cutting
temperatures.
Key words: Grinding, Nano Graphene, Solid Lubrication, Lubrication
Regression Model for Electro-Chemical Aided Abrasive Flow Machining (Eca2fm)
Process
B.S. Brar1*, R.S. Walia2 and V.P. Singh3
Mechanical Engineering Department, PEC University of Technology, Chandigarh, India, 160012,
1*
2
Mechanical and Production Engineering Department, Delhi Technological University, Delhi, India,
3
Mechanical Engineering Department, PEC University of Technology, Chandigarh, India, 160012,
E.mail: [email protected]
Abrasives laden self modulating putty is employed in the Abrasive flow machining (AFM) process for the
fine finishing of mainly complex internal geometries. To improve the machining efficiency of AFM process,
it has been successfully hybridized with the electrochemical machining (ECM) process and this hybrid
process is termed as electro-chemical aided abrasive flow machining (ECA2FM) process. The effect of key
ECA2FM process parameters on the material removal has been experimentally studied through response
surface methodology (RSM). Regression model for material removal was developed for the internal surface
finishing of hollow cylindrical brass components and significant parameters were identified employing
analysis of variance (ANOVA). Significantly higher material abrasion was observed in the ECA2FM
process over AFM due to concurrent material abrasion and erosion due to AFM and ECM machining
actions respectively. This process is suitable for the fine finishing of cylindrical or prismatic shaped cavities
or holes.
Keywords: Abrasive flow machining process, electro-chemical aided machining process, response surface
methodology,
Performance analysis of ball end magnetorheological finishing using sintered magnetic
abrasive based magnetorheological polishing fluid
Mahendra Singh Niranjan1and Sunil Jha2*
Department of Mechanical Engineering, Delhi Technological University, New Delhi 110042, India.
Email [email protected]
2*
Department of Mechanical Engineering, Indian Institute of Technology Delhi, HauzKhas, New Delhi
110016, India,
Email: [email protected], [email protected].: +91-11-2659-1125; Fax: +91-11-2658-2053.
A scheme to finish surface of mild steel in nanometer level and obtain defect free surface/subsurface with
sintered magnetic abrasives based magnetorheological polishing fluid (MRPF) on ball end
magnetorheological finishing (BEMRF) tool is presented. Sintered magnetic abrasives were developed by
uniformly mixing of 20 vol% carbonyl iron powder (CIP) CS grade and 25 vol% silicon carbide abrasives
then sintered in tubular furnace at 12000C using pressureless solid phase sintering method in argon
atmosphere. The sintered product was crushed in ball mill to obtain sintered magnetic abrasives. Particle
characterization was performed with scanning electron microscope and vibration sample magnetometer to
characterize the morphology and magnetizability of sintered magnetic abrasives. MRPF was prepared with
55 vol% base fluid and 45 vol% sintered magnetic abrasives. Experiment was conducted on mild steel
surface with given set of experimental conditions for 30 minutes on BEMRF tool and surface roughness
before and after finishing were measured using Talysurf. Thepercent reduction in surface roughness (% Ra)
was calculated and compared with % Ra obtained by finishing the work-piece surface with unbonded
magnetic abrasives based MRPF having same composition and found superior results. After comparison, a
five level and three factors central composite design of experiments (DOE) was selected to develop the
experimentation plan. Response surface methodology (RSM) was adopted to predict the profile and % Ra
with given set of experimental conditions. An effective second order response surface model was developed
with significant factors and their interactions. Physical interpretation of effect of machining parameters on
% Ra was analyzed.
Keywords:Magnetorheological, Characterization, Sintering, MR finishing, DOE, RSM.
1
Application of Grey Relational Analysis for Geometrical Characteristics in Abrasive
Water Jet Milled Channels
T V K Gupta1*, J Ramkumar2, Puneet Tandon3 and N S Vyas4
1,3
Mechanical Engineering Discipline,
Indian Institute of Information Technology Design & Manufacturing Jabalpur, 482005,
Email:[email protected]; [email protected]
2,4
Indian Institute of Technology Kanpur, India, 208016,
Email:[email protected]; [email protected]
In this study, the effects of process parameters on the geometrical characteristics and the topography were
investigated in milling of SS304 material using Abrasive Water Jet machining technique. In addition,
optimal control of the input variables for achieving the quality of the channel was determined by using Grey
relational analysis. The input process parameters include traverse speed, abrasive flow rate; abrasive size
and standoff distance each at three levels are considered for experimentation. Grey relational analysis was
employed to minimize and maximize the response parameters as per the requirement. Parameters like
surface roughness, taper, impact force, vibration are minimized; depth is maximized and the width of cut is
kept optimum which is the inside diameter of the focusing tube. Based on the grey coefficients and grades
of the experimental data, a traverse speed of 3000 mm/min, a diameter of 0.125 mm of abrasive particle at
0.49 kg/min abrasive flow rate and a standoff distance of 4mm gives an optimum machining conditions for
the required output.
Keywords: Grey relational analysis, Depth, Taper, Width, Surface roughness
Tool Condition Monitoring using Multiple Sensors Approach in the Microendmilling of
Aluminium Alloy (AA 1100)
Prakash M1, Kanthababu M2*, Gowri S3, Balasubramaniam R4 and
John Rozario Jegaraj5
1
CEG, Anna University, Chennai - 600025, E-mail: [email protected]
2
* CEG, Anna University, Chennai – 600025, E-mail: [email protected]
3
CEG, Anna University, Chennai – 600025, E-mail: [email protected]
4
Precision Engineering Division, Bhaba Atomic Research Center, Mumbai-400 085,
5
Defence Research and Development Laboratory, Hyderabad-500 058, E-mail:[email protected]
In this work, tool condition monitoring (TCM) in the microendmilling of aluminum alloy (AA 1100) using
multiple sensors such as acoustic emission (AE), accelerometer (ACC) and cutting force dynamometer is
carried out. The acquired signals were analyzed in time domain, frequency domain and discrete wavelet
transformation (DWT) techniques. The surface roughness (Ra) and ACCRMS show non uniform trend with
tool wear status. The results indicate the feasibility of using the dominant frequency of the AE and ACC
signals for the monitoring of microendmilling operations. The frequency domain analysis also helps to
identify the tool rotational, tool passing and machining frequencies. The dominant machining frequencies of
AE and ACC are identified around as 180 - 270 kHz and 2.44 - 4.77 kHz respectively. The results of DWT,
indicate that the specific energy of the AE signals of level D3 (125-250 kHz) as well as D4 (62.5-125 kHz),
and the specific energy of the ACC signals of levels D2 (2.5-5 kHz) and D3 (1.25-2.5 kHz) are found to be
dominating among the five levels (D1-D5). These levels are correlated with shearing and plastic
deformation modes of material removal mechanism. The cutting force analysis indicates that, the force
component in the feed direction (Fy) is more sensitive with respect to the machining time than the axial (Fz)
and transverse (Fx) directions. This study will be useful to the manufacturers for monitoring the condition of
the tool during microendmilling of AA 1100.
Keywords: Acoustic Emission, Accelerometer, Cutting Force Dynamometer, Time Domain, Frequency
Domain, Discrete Wavelet Transformation
Modeling Electrical Discharge Machining Process Using Artificial Neural Network for
the Machining of Special Steel WP7V
Ranjan Kumar Ghadai 1*, RashmiRanjanBehera2 and Subash Chandra Mondal 3
1* Department of Mechanical Engineering, Bengal Engineering and Science University, Shibpur, Howrah711 103, West Bengal, India, Email- [email protected]
2 Department of Mechanical Engineering, Jadavpur University, Kolkata-700028, India, [email protected]
3 Department of Mechanical Engineering, Bengal Engineering and Science University, Shibpur, Howrah711 103, West Bengal, India, [email protected]
Electrical discharge machining (EDM) is a process for shaping hard conducting materials and forming
intricate shaped holes by spark erosion. The special steel WP7V are highly promising materials for the
applications in many steel industries for making various accessories like high wear loaded dies with flat
impression, hot & cold shear knives, cutting sheet, highly stressed punches, profiling rolls and EDM is one
of the most commonly used manufacturing processes for making intricate impression in any hard
conducting materials. From literature review it has been found that less work has been done on the material
WP7V. Due to stochastic nature of EDM process, perfect relationship between input and output parameters
cannot be made. So modeling by artificial neural network (ANN) is adopted. This study addresses the
modeling of machinability of WP7V. In the present work, a feed forward back propagation artificial neural
network (ANN) is used to model the influence of current and time on material removal rate & surface
roughness. Multilayer perception model has been constructed with feed forward back propagation algorithm
using current and time as input parameters and MRR and average surface roughness (Ra) as the output
parameters. The predicted results based on the ANN model are foundto be in very in a very close agreement
with the unexposed experimental data set. The modeling results confirm the feasibility of the ANN and its
good correlation with the experimental results. The ANN model, thus developed is then used to develop the
response surfaces to investigate the effect of different input parameter.
Keyword: EDM, ANN, MRR, Surface Roughness
Experimental Investigation on Near-dry Electric Discharge Machining
Krishnakant Dhakar1* and Akshay Dvivedi2
Mechanical & Industrial Engineering Department, IIT Roorkee, Uttarakhand 247667
2
Mechanical & Industrial Engineering Department, IIT Roorkee, Uttarakhand 247667
1*
The near-dry electric discharge machining (EDM) is an eco-friendly process. It does not produce toxic
fumes and health hazards. The near-dry EDM generally utilizes water & air mixture as a dielectric medium.
In this study kerosene & air were used as dielectric by near-dry EDM. This investigation reveals the effect
of four process parameters viz current, duty factor, flushing pressure and lift on three responses. The
responses measured were material removal rate (MRR), surface roughness (SR), and tool wear rate (TWR).
The work material chosen was high speed steel (HSS). Mathematical models have been proposed herein for
analysis of the effect of process parameters in near-dry EDM. The models were developed using response
surface methodology (RSM). The experimental results reveal that all the selected process parameters were
significant for MRR. While current and flushing pressure were significant for TWR. Flushing pressure was
only significant process parameter for SR.
Keywords: Near-dry Electric Discharge Machining, Material Removal Rate, Response Surface Methodology
Preliminary Investigation into Finishing of Artificial Dental Crown
Pankaj Baghel1, Shreyansh Singh2, Nikita Dua3+, V.K. Jain4* and Leeladhar Nagdeve5
Department of Mechanical Engineering, IIT Kanpur, Kanpur-208016
+
Rama Dental College, Kanpur-208024
1
2
[email protected], [email protected], [email protected], 4*[email protected], [email protected]
The purpose of a crown is to cover or "cap" a damaged tooth. Metal crowns are casted using lost wax
technique while the latest zirconium crowns are fabricated by CAD-CAM Technique. The surface
smoothness of crown is important for long-standing dental restorations since it directly affects the clean
ability and retention of microbes. Rise in bacterial cell attachment occurs with an increase in the surface
roughness, inducing plaque accumulation which results in periodontal tissue inflammation and accelerated
antagonist wear. The ultimate aim of this research study is to achieve the optimum surface roughness of
dental porcelain crown by finishing the unglazed crowns using the process of Magnetorheological Fluid
based Finishing Process. The surface finish thus achieved by finishing was better than the measured surface
finish of the glazed surface in all the cases except with machining gap of 200 µm.
Keywords: Ceramic, Surface roughness, Polishing, Magnetorheological fluid based finishing (MRFF)
process
Finite Element Modeling for Prediction of Cutting Forces during Micro Turning of
Titanium Alloy
1
Jagadesh T1 and Samuel G L2*
Department of Mechanical Engineering, Indian Institute of Technology Madras, Chennai, India, 600036,
1
E-Mail: [email protected], 2Email: [email protected]
Micromachining of industrial products, is playing an important role in manufacturing of axisymmetricminiaturized parts especially in biomedical and aerospace applications.This paper presents the
development of 3D oblique finite element modeling for prediction of cutting forces, thrust force, feed force,
and tool chip interface temperature during micro turning process. Titanium alloy (Ti6Al4V) and Coated
carbide tool (TiN/AlTiN) is considered as work and tool material respectively. Johnson- Cook material
model with strain gradient plasticity is used to represent the flow stress of the work material. When uncut
chip thickness is equal to or less than the edge radius, thrust force is dominant over the cutting force due to
rubbing and ploughing action. When cutting speed increases there is decrease in cutting force due to thermal
softening effect. When depth of cut and uncutchip thickness is less than edge radius there is increase in
specific cutting energy due to material strengthening effects. Tool chip interface temperature increases by
increasing the cutting speed. Simulated cutting force values are agree well with the experiment values.
Key words: FEM, Cutting forces, Edge radius
Parametric Studies of Abrasive Water Jet Cutting on Surface Roughness Of Silicon
Nitride Materials
1
Debasish Ghosh1, Probal K. Das2and B.Doloi3*
NeotiaInstituteof Technology Management & Science, Diamond Harbour, West Bengal
[email protected]
2
Central Glass & Ceramic Research Institute, Kolkata-700032, [email protected]
3*
Jadavpur University, Kolkata-700032, [email protected]
Abrasive Waterjet Cutting [AWJC] is a rapidly developing technology that is used in industry for a number
of applications including plate profile cutting and machining of a range of materials [1]. It has various
distinct advantages over the other non-traditional cutting technologies, such as no thermal distortion, high
machining versatility, minimum stresses on the work piece, high flexibility and small cutting forces. Dense
Si3N4, is one of the very hard ceramic materials, used for both room and high temperature structural
application, was machined by Abrasive water jet machining technique using Silicon carbide grits (80 B.S.)
in place of commercially used garnet sand. Water pressure, abrasive flow rate, traverse speed and standoff
distance were varied between 5000-6000 bar at 250 bar interval, 10gm/min-20gm/min at an 2.5gm/min
interval, Traverse speed and Standoff distance varied between 1mm/min - 7mm/min at an interval of
1.5mm/min and 4mm-16mm at an interval of 3mm respectively.
Keywords: Si3N4, Abrasive water jet, Surface roughness
Empirical Modelling of MRR in Electrochemical-Mechanical Finishing of Bevel Gears
J. P. Misra1, 2*, P. K. Jain1, D. K. Dwivedi1 and N. K. Mehta1
Mechanical and Industrial Engineering Department, Indian Institute of Technology Roorkee, Roorkee247667, Uttarakhand, India.
2
Mechanical Engineering Department, National Institute of Technology Kurukshetra, Kurukshetra-136119,
Haryana, India.
1
This paper presents the micro-finishing of bevel gears by electrochemical-mechanical finishing (ECMF)
process under different experimental conditions of current, rotating speed of workpiece and electrolyte
concentration. These different experimental conditions are planned on the basis of box behnken design
(BBD) design of experiments (DOE) technique of response surface methodology (RSM). An empirical
model has been developed using artificial neural network (ANN) with feed-forward back propagation
algorithm. The developed ANN model has been optimized and it is observed that the developed model is
quite capable of predicting the material removal rate of the process for different sets of input process
parameters.
Keywords: Electrochemical-mechanical finishing (ECMF), Empirical modelling, Artificial neural network
(ANN).
Effect of Layer Thickness in Micro Electric Discharge Milling: An Experimental
Investigation
Jafferson JM 1*, Hariharan P2 and Ram Kumar J3
Department of Manufacturing Engineering, CEG, Chennai-600025, [email protected]
2,
Department of Manufacturing Engineering, CEG, Chennai-600025, [email protected]
3
Mechanical Engineering Department, IIT Kanpur-208016, [email protected]
1*,
Machining of high aspect ratio micro channels and cavities in metals is a challenging task. Micro Electric
Discharge milling is an exciting process which is capable of micromachining of all electrically conductive
materials. The aim of this study is to analyse the effects of layer thickness on Material Removal Rate
(MRR), Tool Wear Rate (TWR) and Relative Electrode Wear (REW) while micro Electric Discharge (µED)
milling of stainless steel using Tungsten electrode. The study revealed that layer thickness along with tool
rotational speed and horizontal feed rate of the tool significantly influences the performance of µED milling.
Keywords: Micro channel; micro EDM; Layer Thickness; MRR; Tungsten; TWR
Modeling and Analysis of Micro-WEDM Process on Inconel Super Alloy through
Response Surface Methodology
Sivaprakasam.P1*, Hariharan.P2 and Gowri.S3
Department of Manufacturing Engineering, College of Engineering Guindy,
Anna University, Chennai, 600025, India, [email protected].
2
Anna University, Chennai, 600025, India, [email protected].
3
Anna University, Chennai, 600025, India, [email protected]
1*
This paper presents modeling and analysis of machining characteristics of micro wire electro discharge
machining (micro-WEDM) process on inconel alloy 718 using the response surface methodology (RSM).
The input variables of micro-WEDM process are voltage, capacitance and feed rate. The material removal
rate is considered as a response variables. Experiments were carried out on inconel alloy 718 using central
composite design (CCD). The RSM models have been developed based on experimental designs. Analysis
of variance (ANOVA) has been employed to test the significance of RSM model. It has been found out that
all the three process parameters are significant and their interaction effects are also significant on the MRR.
Finally predicted values were compared with experimental values.
Keywords: Micro-WEDM, ANOVA, Inconel alloy
Experimental Investigation of the Process Parameters in Abrasive Waterjet Cutting of
Redmud Reinforced Banana/Polyester Hybrid Composites
M.Uthayakumar1*, V.Arumugaprabu2 and M.Kathiresan3
Department of Mechanical Engineering, Kalasalingam University, Krishnankoil-626126, [email protected]
2
Department of Mechanical Engineering, Kalasalingam University, Krishnankoil-626126, [email protected]
3
Department of Mechanical Engineering, Thiagarajar College of Engineering, Madurai-625015, [email protected]
1*
This work deals with the assessment of the process parameters in abrasive waterjet cutting of redmud
reinforced banana/polyester hybrid composite. The composite was prepared through compression molding
technique with varying weight percentage of redmud viz. 10%,20% and 30%. Investigation has been
conducted to assess the influence of the input parameters on the output responses such as material removal
rate, top kerf width, bottom kerf width and kerf angle of the composite. Experiments are carried out using
L27 orthogonal array, by varying the water pressure, traverse speed and percentage of redmud for the
composite. Analysis of variance was also carried out to study the effect of each input parameters on the
output responses. From the study it is observed that the water pressure is the most significant parameter on
composite cutting than others.
Keywords: Redmud, Banana Fiber, Polyester, Abrasive waterjet machine.
Investigation of µED-milled Tapered Channels for Microfluidic Devices
Pranit Deshmukh1, Saurabh Annadate2 and G.Karthikeyan3*
1,2
Dept. of Mechanical Engg, BITS Pilani, Goa campus, 403726,
3
Dept. of Mechanical Engg, BITS Pilani, Goa campus, 403726, [email protected]
Micro Electric Discharge milling (µED-milling) process is thermal erosion process in which metal is
removed by a series of recurring electrical discharges between a cutting tool acting as an electrode and a
conductive workpiece, in the presence of a dielectric fluid. One of the main applications of this process is
the manufacturing of open micro-channels for microfluidic fluid flows. This article focuses on generating
tapered micro-channels of different angles by µED-milling process and studying the phenomenon on fluid
flow through them. Through experimentation different channels are milled with a conventional straight tool
electrode at various machining conditions. Due to the phenomenon of tool wear in µED-milling process, the
channels generated are tapered both at the side and bottom. Even though most literature considers taper
formation as a drawback of µED-milling process, this article presents an advantage of taper for real time
fluid flow applications. The article investigates pressure driven liquid flow through micro-channels using
Computational Fluid Dynamic tools. The variations in pressure and velocity are studied and the results are
compared for flat open micro-channel and tapered open micro-channels.
Keywords: Electrical Discharge Machining, Fluid Flow, Micro-channel
Dynamic Stability of High Speed Micromilling Based on Modal Analysis for
Determining the Tool-tip Dynamics
Kundan Kr. Singh1, V. Kartik2 and Ramesh Singh3*
Department of Mechanical Engineering, Indian Institute of Technology Bombay, Powai, Mumbai-400076, India
Email: [email protected], [email protected], 3*[email protected]
Micromilling process is used for fabrication and manufacturing of miniaturized components. Very high
spindle rotational speeds are required in micromilling to reduce the chip load and to counter the low flexural
rigidity of the micro-tool while machining hard materials. Apart from the high rotational speed (>100,000
rpm) which can excite dynamic instability, the dynamic force variation in micromachining can also occur
due to micro-machine tool system limitations (limited tool stiffness and misalignments), micro scale cutting
mechanics (critical chip thickness and size effect) and material inhomogeneity. The dynamic instability can
induce surface/form errors and can result in catastrophic tool failure. This paper is focused on developing a
two-degree of freedom model of the micromilling process for predicting chatter via stability lobe diagram.
The dynamics of the cutting tool has been predicted by finite element analysis. After prediction of tool tip
dynamics, the cutting coefficient has been determined experimentally. Finally, the dynamic stability has
been predicted after considering the regenerative effect. Experimental verification of predicted stability
shows the good agreement between analytical and experimental chatter free depth of cut and cutting speed.
Hence, modal analysis by FEM can efficiently be used for determination of the tool tip dynamics. The
predicted stability lobe diagram can be used for selection of chatter free combination of depth of cut and
cutting speed prior to machining of Ti6Al4V.
Keywords: Micromilling, Chatter modeling, Modal analysis of micro end mill, Stability lobes
Optimization of Multiple Performance Characteristics of the Electrical Discharge
Machining Process on Metal Matrix Composite (Al/5%Ticp) using Grey Relational
Analysis
V. Chittaranjan Das1*and N.V.V.S. Sudheer 2
R.V.R & J.C. College of Engineering, Guntur - 522 019, Andhra Pradesh, India
2
R.V.R & J.C. College of Engineering, Guntur - 522 019, Andhra Pradesh, India
1*
Electrical discharge machining (EDM) is an effective tool in shaping difficult-to-machine metal matrix
composites (Al/5%TiCp) to a high degree of accuracy and surface finish. The metal matrix composites used
for the tests were Aluminum composites reinforced with 5% of titanium carbide particles (TiCp) produced
through the powder metallurgy route. In the present study, an L9 orthogonal array (OA), the process
parameters included discharge current, open voltage, pulse ON time and duty cycle with three levels each
has been selected. The material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR) was
selected as the evaluation criteria. Optimal combination of process parameters is determined by the grey
relational grade (GRG) obtained through GRA for multiple performance characteristics. Analysis of
variance for the GRG is also implemented. The optimized process parameters simultaneously leading to
higher material removal rate, a lower electrode wear ratio and better surface roughness are then verified
through a confirmation experiment. The validation experiments show the machining performance of the
material removal rate increases from 2.92 to 3.69 mg/min, the electrode wear ratio decrease from 0.13 to
0.10mg/min and the surface roughness decreases from 2.21 to 1.93 m, respectively. Empirical expressions
of EDMed parameters relationship with the MRR, TWR and SR were developed which are promising in
estimating the observed values.
Keywords: Electrical discharge machining (EDM), Metal matrix composite, Taguchi Method, Gray
relational analysis.
Application of Abrasive Water Jet Machining in Fabricating Micro Tools for Edm for
Producing Array of Square Holes
Vijay Kumar Pal1*and S.K. Choudhury2
Ph.D. Scholar, Indian Institute of Technology Kanpur, Kanpur, 208016, Email: [email protected]
2
Professor, Indian Institute of Technology Kanpur, Kanpur, 208016, Email: [email protected]
1*
In the field of Abrasive Water Jet (AWJ) machining, the current focus is on the fabrication of complex
three-dimensional features. The current work is aimed at using this strategy to manufacture micro-tools for
machining arrays of square holes using Electric Discharge Machining (EDM). Based on selected parameters
of AWJ process (step over, traverse speed, path strategy), micro tools were fabricated on brass sheet of 6
mm thickness.The performance of such fabricated tool was investigated by performing experiments on
EDM machine to make arrays of square blind holes( texture ) on stainless steel and Ti-6Al-4V alloy sheet.
The depth of texture was measured through 3D profilometer of FOV (2x) and objective (5x) embedded with
vision 64 software.The textured square holes were obtained and its depth was achieved in the range of 10 to
60 microns and the corresponding depth obtained of the texture is less on titanium. Discrepancy between
the tool dimension (square) and work piece (textured) was found because of the tool wear on the electrode.
Keywords: AWJM, Texturing, EDM, Electrode (Tool)
Application of Pure Water Jet Machining For Improving Surface Finish of Parts
Fabricated by Abrasive Water Jet Machining
Vijay Kumar Pal1*and S.K. Choudhury2
Indian Institute Of Technology Kanpur, Kanpur, 208016, Email: [email protected]
2
Indian Institute Of Technology Kanpur, Kanpur, 208016, Email: [email protected]
1*
Fabrication of 3-D features is a major research interest in Abrasive Water Jet (AWJ) process, but the poor
surface quality of machined components restricts the process for being widely used. Present work initially
focuses on fabrication of micro channels by AWJ and analyses the effect of process parameters namely
pressure, traverse speed and stand-off distance on depth and surface finish of samples machined.
Experiments were performed on Ti-6Al-4V alloy of 1 mm thickness sheet and Central rotatable Composite
Design (CCD) test matrix with an alpha value of 1.68 was used for design of experiment. The correlations
between the process parameters and responses like depth and surface roughness were established by
multiple linear regression models. Experimental observations show that the depth is affected most by
pressure, followed by traverse speed. The combination of high pressure and fast traverse speed results in a
quite smooth surface because high pressure provides sufficient jet energy for smooth fracture. Second part
of this paper presents an innovative path strategy to improve surface quality of machined samples. Here,
AWJ was used for rough/stock removal of material followed by pure water jet (PWJ) along the same path
(movement of the nozzle) as a final cut to improve surface quality of machined samples. 3-D optical
profilometer with objective lens (5x) and field of view (FOV 2x) along with the SPIP software was used to
measure geometry and profile of slots. Digital microscope of 230x and a scanning electron microscope
(SEM) were used to observe and analyse the micro structure of the machined pockets. The SEM
investigation demonstrated that for all the samples machined by PWJ (as finishing pass), the material
removal mechanism is uniform and surface was found smoother than in case of AWJ and embedded
particles were also removed to a certain extent.
Keywords: Abrasive water jet (AWJ), Pure water jet (PWJ), Traverse speed, 3-D optical profilometer, SEM
Estimation of Machining Performances of P-20 Material in Wire Electric Discharge
Machining using Group Method Data Handling Technique
G.Ugrasen1*, H.V.Ravindra2 and G.V.Naveen Prakash3
1*
Department of Mechanical Engineering, BMS College of Engineering, Bangalore-560 019, E-mail:
[email protected]
2
Department of Mechanical Engineering, PES College of Engineering, Mandya-571 401,
3
Department of Mechanical Engineering, VidyaVardhaka College of Engineering, Mysore-570 002, E-mail:
[email protected]
Wire Electrical Discharge Machining (WEDM) is a specialized thermal machining process capable of
accurately machining parts with varying hardness or complex shapes, which have sharp edges that are very
difficult to be machined by the main stream machining processes. This study outlines the development of
model and its application to optimize WEDM machining parameters using the Taguchi’ s technique which is
based on the robust design. Experimentation was planned as per Taguchi’ s L’ 16 orthogonal array. Each
experiment has been performed for P-20 steel material under different cutting conditions of pulse-on, pulseoff, current, and bed speed. Among different process parameters voltage and flush rate were kept constant.
Molybdenum wire having diameter of 0.18 mm was used as an electrode. Machining responses namely
accuracy, surface roughness, volumetric material removal rate and electrode wear have been considered for
each experiment.Based on this analysis, process parameters are optimized. Estimation and comparison of
machining performances was carried out using group method data handling technique (GMDH).
Key Words: WEDM, Taguchi’ s technique, Estimation, GMDH.
Parametric Analysis of Electrochemical Discharge Micro-Machining Process during
Profile Generation on Glass
1
B.Mallick*, 2M.N. Ali, 3B. R.Sarkar, 4B.Doloi and 5B.Bhattacharyya
Production Engineering Department, Jadavpur University, Kolkata-32
1-5
Electrochemical discharge micro-machining (micro-ECDM) has the ability to machine electrically nonconducting materials as compared with different existing traditional and also non-traditional machining
processes. This paper deals with the effects of different process parameters like applied voltage (V),
electrolyte concentrations(wt%), pulse frequency and duty ratio on different machining performance
characteristics such as material removal rate (MRR), overcut (OC) and heat affected zone (HAZ) during
micro-profile generation on electrically non-conducting glass. Applied voltage has been set from 35-55 V
and the electrolyte concentration, pulse frequency and duty factor were varied from 10-30wt%, 200Hz-1kHz
and 45-65% respectively during the experimentation. A cylindrical shaped stainless tool of diameter 350 µm
and NaOH solution as electrolyte were used to conduct the experiments. Material removal rate is high for 55
V and 30 wt% electrolyte concentration respectively. Overcut and HAZ area decreases with frequency
whereas it increases with duty ratio after 50% and 55% of duty ratio respectively.
Keywords: µ-ECDM, µ-channel, MRR, OC, HAZ
Modeling and Analysis of Cutting Forces in Micro End Milling
1*, 2
Tej Pratap1*and Karali Patra2
Department of Mechanical Engineering, IIT Patna, Patna, 800013,
E-mail: 1*[email protected], [email protected]
Micro end milling is one of the widely used processes for producing micro features/micro components in
micro-fluidic systems, biomedical applications, aerospace applications, electronics and many other fields.
However in these applications, the forces generated in the micro-end milling process can cause vibration
and process instability and even cause tool breakage if not minimized. Therefore, an accurate prediction of
cutting forces in micro-end milling is essential. In the present study a finite element method based model is
proposed for prediction of cutting forces in micro end milling with due consideration of material behaviour,
tool edge radius effect and fracture behaviour of the work piece material including friction parameter at
tool-chip interface. Micro slots are produced on copper plate using 500 µm dia. tungsten carbide micro-end
mill and experimental cutting forces are acquired through dynamometer. Model predicted cutting forces
(feed force and tangential force) are compared with experimental cutting forces and are found to be in good
agreements.
Keywords: Cutting forces, Micro end milling, Micro-fluidic devices, FEM
Parametric Analysis of CNC EDM on OHNS Tool Steel
1
K. Saraswathamma* and 2Madhu Durgam
Mechanical Engineering Department, Osmania University, Hyderabad-7
2
Mechanical Engineering Department, Osmania University, Hyderabad-7
1*
Electrical Discharge Machining (EDM) is well known unconventional machining and capable of machining
geometrically complex and hard material components, that are precise and difficult-to-machine such as heat
treated tool steels, composites, super alloys, ceramics, carbides, heat resistant steels etc. In the present work,
detailed study through statistical design of experiments were carried out to study the effect of machining
parameters such as Pulse current, Pulse on time(Ton) and Pulse pause time(Toff) on responses variables
such as Material Removal Rate(MRR) and Tool Wear Rate (TWR) on OHNS Tool Steel. The experiments
were designed using Response surface methodology (RSM) - Central Composite Design (CCD) involving
three variables with three levels. An attempt has been made to develop mathematical model for relating the
MRR and TWR to the input parameters. Separate Analysis of Variance (ANOVA) are conducted and
contribution of each parameter affecting improvement in MRR and TWR is calculated. Investigation results
indicates that MRR and TWR increases with increase in pulse current and pulse on time.
Key words: CNC EDM, OHNS, Pulse current, Pulse on time (Ton), MRR, TWR.
Comparison of Process Mechanics In µEDM-Drilling And RµEDM Based on Online
Monitoring of Discharge Gap Condition
C K Nirala1 and P Saha2*
Indian Institute of Technology Patna, Patna, India, Email: [email protected]
2*
Indian Institute of Technology Patna, Patna, India, Email: [email protected]
1
The pulse generator in RC circuit based micro electrical discharge machining (µEDM) produces different
size of pulses which results in pulses of non-isoenergetic nature. The occurrence of various sized pulses at
various intervals reveals the dynamic of the work-tool interface of µEDM process. This dynamic gap
condition may also cause variation in the responses such as percentage of contributing pulses, average
energy, histogram of discharge energy and material removal per discharge as machining progresses. These
dynamic responses are also expected to be different for different µEDM variants. Therefore, the aim of this
study is to compare the process mechanics of two different µEDM variants called µEDM-drilling and
reverse µEDM (RµEDM) based on the aforementioned dynamic responses. Process mechanics basically
refers to the mechanism of debris removal and consequently stability of the process. In order to carry out
this research a new pulse discriminating (PD) system has been developed. The results reveal that RµEDM
process is more stable than µEDM-drilling.
Keywords:Reverse µEDM, non-isoenergetic, process mechanics, frequency distribution histogram
Development and Experimental Investigation of Electro-Discharge Diamond Face
Grinding
Sanjay Singh1, Vinod Yadava2 and Ram Singar Yadav3*
MED, MNNIT Allahabad, Allahabad, India, [email protected]
2
3*
1
Electro-Discharge Diamond Face Grinding (EDDFG) is an advanced hybrid machining process for face
grinding of wide variety of electrically conductive difficult-to-machine hard materials by suitable
modification in Electro-Discharge Machining (EDM). In the present work, the EDDFG setup has been
developed and tested for grinding difficult-to-machine materials and also attempted for fabrication of metal
matrix composite of Aluminium (Al) reinforced by 10% Silicon Carbide (SiCp). To perform such hybrid
machining process, the developed experimental setup was used for experimental study of EDDFG process
on Al-SiCpMMCby considering the effect of gap current, pulse on time and wheel RPM on average surface
roughness (Ra) and material removal rate (MRR). The metal bonded diamond abrasive grinding wheel is
mainly responsible for higher value of MRR. It was also observed that MRR is higher at moderate value of
wheel RPM and wheel rotation improves the flushing action. The average surface roughness (Ra) was
observed better at low values of gap current, pulse on time and wheel RPM. The present developed EDDFG
setup has proven to be successful for machining of difficult-to-machine materials. Texture of the machined
surface has been studied using Scanning Electron Microscope (SEM).
Keywords: Electro-Discharge Diamond Face Grinding (EDDFG),Al-SiCp MMC, MRR and Ra
Machinability Assessment of Superni-800 during EDM With Powder Metallurgy
Processed Cu-Ti Electrode Using the Taguchi Method
Vijay Kumar Bhanot1*, Naveen Beri 2 and Anil Kumar3
Department of Mechanical Engg. Amritsar College of Engineering & Technology, Amritsar, Punjab, India,
143001
2
Department of Mechanical Engg. Beant College of Engineering & Technology, Gurdaspur, Punjab, India,
143521
3
Department of Mechanical Engg. Beant College of Engineering & Technology, Gurdaspur, Punjab, India,
143521
1
Electrical discharge machining (EDM) is a prominent machining process among newly developed nontraditional machining processes and electrodes made through powder metallurgy (PM) technique has given
an alternative tooling option to the researchers. In the present experimental investigation, blind holes were
machined using PM processed copper- titanium (Cu-Ti) electrodes and conventional copper electrode
during electric discharge machining of Superni-800. The Taguchi’ s experimental design and analysis of
variance (ANOVA) techniques have been implemented to understand the effects, contribution, significance
and optimal machine settings of process parameters, namely, polarity, peak current, electrode type, pulse on
time and gap voltage on material removal rate (MRR) and wear ratio (WR). The significant parameters that
critically influenced the machinability were examined, and the optimal combination levels of machining
parameters for MRR and WR were determined. It was found that Cu-Ti powder metallurgy processed
electrode gives higher MRR and WR resulting in better machinability of Superni-800.The results were
verified through confirmation experiments.
Keywords: EDM, Taguchi method, powder metallurgy, wear ratio, material removal rate
Comparative Evaluation of Mechanically Alloyed and Sintered Magnetic Abrasives for
Fine Finishing
Sehijpal Singh1*, Parmjit Singh2 and H.S Shan3
G. N.D. Engineering College Ludhiana-141006, [email protected]
2
Dr.B.R.Ambedkar NIT, Jallandhar-144001,[email protected]
3
Punjab Technical University, Kapurthala-144601, [email protected]
1
The magnetic abrasives play a vital role as cutting tool in the performance of magnetic abrasive finishing
(MAF) process. In this paper, a comparison has been made between the performance and characteristics of
magnetic abrasives prepared by a newly developed technique (Mechanical alloying) and a common
technique (Sintering). Mechanical alloying and sintering process have been used to prepare magnetic
abrasives having 15% SiC and 85% Fe as constituent powders. An experimental set up was developed for
the conduct of experimental work. The experiments were conducted to examine the effect of mesh size of
magnetic abrasives and machining time on the performance when MAF is done on Stainless Steel 304 with
sintered magnetic (SM) abrasives and mechanically alloyed magnetic (MAM). The amount of lubricant,
rotational speed of work piece, magnetic flux density and quantity of magnetic abrasives and initial surface
roughness of the tube surface were taken as constant parameters. The performance parameter was taken as
percentage improvement in surface finish (PISF).The best surface finish in the range 0.01-0.04 µm was
achieved on internal surface of SS 304 tube. The MAM abrasives with mesh size 52 gave best finishing
results along with a good life. The SM abrasives with mesh size 130 and 180 also gave comparable results
but the life of these abrasives was not as good as that of MAM abrasives.
Keywords: Magnetic Abrasive Machining, Mechanical alloying, Sintering, Surface finishing
Abrasive Flow Finishing Process— A Case Study
T. S. Kavithaa1, N. Balashanmugam2 and P. V. Shashi Kumar3
Central Manufacturing Technology Institute, Bangalore 560 022
[email protected]
[email protected]
[email protected]
The emergence of Abrasive Flow Finishing/Machining (AFFM) as an advanced fine finishing process is
attributed towards the need for relaxation of tool limitations, relative motion of work piece with respect to
tool and precise finishing of complex geometries and internal passages in components. Herein, the abrasive
laden polymer media conforms to the work piece geometry overcoming shape limitation inherent in
conventional finishing processes. The paper outlines the various functionalities of the AFFM system
developed and the experimentation carried out for finishing and deburring of modular head of a hip joint,
extrusion die and shuttle valve used in bio-medical, aerospace and pharmaceutical industries respectively
are discussed. Surface characterization of the finished components using optimized process parameters are
discussed in detail. The reported results signify the versatility and deterministic aspect of the developed
AFFM machine for surface finishing of ferrous and non-ferrous components.
Keywords: Abrasive Flow Machining, Roughness, Radiusing, Deburring
An Experimental Investigation during Nano Finishing of Hybrid
Al/ (Al2O3+ZrO2)-MMC on Developed ECG Setup
Alakesh Manna* and K.Z. Molla
* Department of Mechanical Engineering, PEC University of Technology, Chandigarh-160012, e-mail:
[email protected]
Department of Mechanical Engineering, Chitkara University
Rajpura, Punjab Campus, Punjab-140401.e-mail: [email protected]
This paper presents the influence of electrochemical grinding (ECG) process parameters on surface
roughness height, Ra during nano finishing of Hybrid Al/ (Al2O3+ZrO2) MMC. An electrochemical grinding
(ECG) setup has been designed and fabricated. The fabricated ECG setup is utilized for experimental
investigation. A metal bonded diamond grinding wheel is used to finish internal surface of cylindrical
workpiece. Analysis of variance (ANOVA) is done to identify the most significant process parameters and
percentage of contribution of each parameter on surface roughness height, Ra (µm). Test results prove that
the surface roughness height, Ra (µm) reduced from 1.40 µm to 96 nm. It reveals a considerable
improvement in the surface finish Ra.
Keywords: Electrochemical Grinding (ECG), Surface Finish, Hybrid MMC.
Ultra High Finishing Of Oval Bores Using Elastic Abrasive Balls
V.S. Sooraj* and V. Radhakrishnan
Department of Aerospace Engineering
Indian Institute of Space Science and Technology
Valiamala, Kerala, India-695547
Ultra fine finishing of engineering surfaces using elastic abrasive balls is a simple, flexible, multi
application oriented-cost effective approach developed in the recent past. Considering the industrial
relevance, the application of such balls for fine finishing of an intricate oval bore is presented in this paper.
In this methodology, abrasive grains are flexibly bonded in the form of meso scale balls using an
elastomeric medium which will facilitate the balls to deform in conformity to the work surface, thereby
producing fine refinement of surface profile. Major process variables involved in the operation as well as
the influence of these parameters in surface roughness of the bore are discussed in detail. Remarkable
improvement in finish, almost 85 % reduction in average roughness (Ra) is noticed after the use of elastic
abrasives for a processing time of 45 minutes, yielding a final Ra value of 25 to 30 nm, without altering the
oval form.
Keywords: Elastic-abrasive balls, Fine finishing, roughness
An Experimental Investigation During Micro Drilling of Hybrid Al/(Al2O3p+SiCp+Cp)MMC on Developed ECMM Setup
C. S. Kalra1*, Alakesh Manna2and V. K. Singla3
SUS Group of Colleges, Mohali -140110,[email protected]
2
PEC University of Technology, Chandigarh-160012, [email protected]
3
Thapar University, Patiala -147001, [email protected]
1*
This paper presents the effects of various parameters of fabricated electro chemical micro machining
(ECMM) setup on machining response characteristics during micro drilling of Hybrid
Al/(Al2O3p+SiCp+Cp)-MMC. An ECMM setup has been designed and fabricated for the purpose. Fabricated
ECMM setup has different units such as mechanical machine unit, electrical power supply and control unit,
electrolyte flow and control unit, servo control and electrode feed unit. From the experimental results, it is
clear that the MRR increases with increase in supply current, supply voltage, pulse on time and electrolyte
concentration but at same time overcut, and taper are also increased. During micro drilling, it is also observe
that very low dimensional micro tools are not suitable for ECMM operation because of high tool wear by
electrochemical dissolution. In this investigation, micro holes are generated with 271µm diameter steel
micro tools. From experimental results, it is clear that the developed ECMM setup can be effectively used
for generation of very fine micro holes on hybrid MMC workpiece.
Keywords:ECMM, Hybrid Al/(Al2O3p+SiCp+Cp)-MMC, average radial overcut, MRR, taper cut
Multi Response Optimization of Ultrasonic Machining Parameters Using Weighted
Principal Component Analysis
1
N.D. Badgayan1and P.S. Rama Sreekanth1*
National Institute of Science and Technology, Odisha, 761008,
*
In this paper, based on historical data three parameters i.e. Grit size, Power and Tool type were varied to
investigate its effect on responses i.e Material Removal Rate (MRR),Tool Wear Rate (TWR) and Surface
Roughness (Ra) for work piece machined by Ultrasonic Machining (USM) process An attempt has been
made to find optimal solution for the responses using Weighted Principal Component Analysis
(WPCA).Analysis of data has found that responses were highly correlated with correlation coefficient
(r=0.905) which justifies the application of WPCA as an optimization tool. The optimal parameter setting
obtained after analysis was exonerated with valid altercation.
Keywords: Ultrasonic Machining, Weighted Principal Component Analysis, Multi Output Performance
Index
Analysis of parametric effects on response characteristics and faults diagnosis during
WEDM of Al/SiCp-MMCs
Harmesh Kumar1*, Alakesh Manna2and Rajesh Kumar3
1
Deptt. of Mech. Engg., SLIET, Longowal-148106,
Punjab (India), Email: [email protected]
2
Deptt. of Mech. Engg., PEC University of Technology
Chandigarh-160012, (India), Email: [email protected]
3
Deptt. of Mech. Engg., SLIET, Longowal-148106,
Punjab (India), Email: [email protected]
The paper analyzes the effects of WEDM parameters on response characteristics including cutting speed,
surface roughness, spark gap and wire breakage in wire electric discharge machining of Al/SiCp-MMC.
This study also examines and identifies the various faults occurred on the machined surface and analyses
their causes. The machined workpiece surface and wire electrode surface morphology have been
investigated during machining. Wire deflection, burning spots, band marks, craters formed etc. during
machining are the important faults which deteriorates the machined surface textures. The presence of
percentage of hard reinforced SiC particulates in MMCs and machining parameter pulse on time have great
effects on response characteristics. The wire breakage could be reduced by appropriate setting of
parameters pulse off time and spark gap set voltage. This research outcome suggested the range of
parameters for stable machining of Al/SiCp-MMC with minimum chances of wire breakage and wire
deflection. This range can be utilized to optimize the WEDM parameters for better machining performance.
Keywords:WEDM parameters, Al/SiCp-MMC, Fault diagnosis
Improved Cooling Unit with Automatic Temperature Controller for Enhancing the
Life of Ice Bonded Abrasive Polishing Tool
S.Rambabu1 and N. Ramesh Babu2*
1
Indian Institute of Technology Madras, Chennai 600 036, E-mail: [email protected]
2*
Indian Institute of Technology Madras, Chennai 600 036, E-mail: [email protected]
This paper presents an improved refrigeration unit with in-built cooling bath and automatic temperature
controller for Ice Bonded Abrasive Polishing (IBAP) system. The polishing tool is prepared by freezing a
slurry of water and fine abrasives with coolant (Isopropyl alcohol) being circulated around the tool holder.
In the earlier setup, the preparation of tool took about 5 to 6 hours, since ethylene glycol is circulated
through heat exchanger of refrigeration unit in order to reduce its temperature from ambient to -12°C. The
temperature of coolant was maintained by manually controlling the refrigeration unit. The current
refrigeration unit with in-built cooling bath aids in pre-cooling the coolant before it is circulated around the
tool holder in IBAP setup. This arrangement could prepare the tool in about 2 hours, thus permitting the tool
to polish the specimen for a longer duration. Preliminary experiments on polishing of flat Ti-6Al-4V
specimen demonstrated the effectiveness of IBAP process by producing very good improvement in finish.
The experimental results showed the promise of nano level finish with removal of cracks existing on the
surface of Ti-6Al-4V specimen.
Keywords: Ice bonded, Polishing, Refrigeration, Controller
Modeling and Optimization for Drilling of High Aspect Ratio Blind Micro Holes in Micro EDM
Swapan Barman1*, Koustov Mondol2, Nagahanumaiah3 and Asit Baran Puri4
1*
CSIR-Central Mechanical Engineering Research Institute, Durgapur-713209
E-mail : [email protected]
2
Kanksa Academy of Technology and Management, Panagarh-713148
3
CSIR-Central Mechanical Engineering Research Institute, Durgapur-713209,
4
National Institute of Technology (NIT), Durgapur-713209, India
In this communication, an attempt was taken to study the influence of machining parameters like gap
voltage, capacitance and depth of hole on machining performances for 2D and 3D surface finish of blind
micro holes and electrode wear length in micro electrical discharge drilling (MEDD) process. The
experimentation was carried out employing full factorial design (33) with three levels of each machining
parameter to study simultaneous effect of factors on machining performance. Mathematical models have
been developed for the mentioned machining outputs by multiple linear regression analysis. Response
surface methodology was utilized to carry out multiple response optimization and to find the optimum
process parameter settings for a desired yield by contour overlapping method using statistical software
MINITAB 16 with 95% confidence level and with levels of factors in coded units. The models so developed
are excellent for acceptance as the coefficients of multiple determinations (R2) for the above responses were
computed as 97.18%, 97.79% and 98.90% respectively. From the models, it was revealed that capacitance,
gap voltage and depth of hole influence Ra, Sa and electrode wear length very strongly. Surface plots and
contour plots were generated to find out the relationship between the machining parameters and the output.
The optimum parametric settings for the machining parameters were computed from overlaid contour plots.
The proposed models could be considered as valuable tools for the process planning of MEDD leading to
cost effective machining of blind micro holes in industry.
Keywords: MEDD, Surface texture Ra and Sa, Full factorial design, optimization
Developing Alternative Polymer Abrasive Gels for Abrasive Flow Finishing Process
Harlal Singh Mali 1*and Jai Kishan2
Malaviya National Institute of Technology, Jaipur, 302017, [email protected],
2
Malaviya National Institute of Technology, Jaipur, 302017, [email protected]
1*
Abrasive Flow Finishing (AFF), a process which was introduced during the late 1960s have emerged as an
important non-traditional metal finishing process and is increasingly being utilized in recent years. The AFF
process has its application in a wide range of industries such as aerospace, defense, surgical and tool & die
manufacturing. During finishing by AFF the peaks of the rough surface get smoothened when abrasive
laden visco-elastic media is extruded over the complex surfaces. In AFF, the media is the key elements that
dominate the finishing behavior. However, commercially available abrasive media are very expensive and
its affordability is an issue, especially for price sensitive industries. Lower-cost alternative AFM media are
developed which consists of base polymers, additives and liquid synthesizer by uniformly mixing them to
become the flexible polymer abrasive gels. Effects of abrasive concentrations, temperature, abrasive mesh
size and percentage of liquid synthesizer on viscosity of polymer abrasive gel have been studied to
characterize the rheology of developed gels. Developed gels are further used to finish the inner surface of a
High Speed Steel (HSS) trim dies in a commercially available Abrasive Flow Machine (AFM) setup with
design & developed AFF tooling and the results are comparable with commercial AFM media. Scanning
Electron Micrographs have been used to visualize the bonding between polymer base and abrasive particle.
After machining the polymer abrasive gel does not stick on the work-piece surface. It is found that the
average surface roughness (Ra) decreased from 3.5 to 0.60 µm after fifty machining cycles and 60weight
percentage abrasive concentration.
Keywords: Abrasive flow finishing; Polymer abrasive gel; Additive Polymer, HSS Trim Dies, Rheology
Modelling and Prediction of Material Removal Rate in Electrical Discharge Diamond
Surface Grinding Process of Inconel-718
Harlal Singh Mali1*, Deepak Unune2and Sandeep Tiwari3
2
3
1*
Hybrid machining processes (HMP’ s) are gaining popularity to machine difficult to cut materials with
competitive pricing with the conventional ones. After establishing the machining capability of the designed
& developed electrical discharge diamond surface grinding (EDDSG) setup aim of this paper is to develop
model for EDDSG of Inconel-718 for predicting its material removal rate (MRR); one of the parameter of
cost effective machining. The effectiveness of the process is also verified through Scanning Electron
Microscope (SEM) micrographs before and after the EDDSG. Response Surface Methodology (RSM),
employing face centered central composite rotatable design (CCRD) scheme, has been used to plan and
analyze the experiments. The mathematical relation between EDDSG input parameters i.e. wheel speed,
pulse current, pulse on-time and duty factor with MRR is established. Artificial neural network (ANN)
technique is used for modeling purpose along with RSM. Predicted values of MRR by RSM and ANN are in
good agreement with the experimental results and will be of direct use by the machining engineer at the
shop floor.
Keywords: EDDSG, Inconel-718, Response Surface Methodology, Scanning Electron Microscope
Chemo-Ultrasonic Assisted Magnetic Abrasive Finishing: Experimental Investigations
Nitesh Sihag1, Prateek Kala2 and Pulak M Pandey3*
1
IIT Delhi, 110016, E-Mail:[email protected]
2
IIT Delhi, 110016,E-mail:[email protected]
3*
IIT Delhi, 110016, E-mail:[email protected]
Chemo-Ultrasonic Assisted Magnetic Abrasive Finishing (CUMAF) is a compound finishing process, which
integrates the use of CMP (Chemo-Mechanical Polishing), ultrasonic vibrations and MAF(Magnetic
Abrasive Finishing), to finish surfaces up to nano meter order within a short span of time. The present work
is focused on designing and fabrication of experimental set up to perform CUMAF. Using this set up
experiments have been conducted on copper alloy work piece and the effects of various process parameters
like percentage weight of abrasive, oxidizing agent concentration, rotational speed of magnet, working gap
and pulse on time of ultrasonic vibration on process response namely percentage change in average surface
roughness value (% Ra) was recorded. The experiments were planned using response surface methodology.
Experimental data was analyzed using analysis of variance to understand contribution of various process
factors and interactions on process response. Regression model was developed to predict the percentage
change in surface roughness in terms of significant process factors and interactions. Further the developed
model was validated and was optimized using genetic algorithm to maximize the performance of the
developed process.
Keywords: Magnetic Abrasive Finishing, ultrasonic vibrations , surface roughness
An Investigation of Wire Electric Discharge Machining of High Temperature Titanium
Alloy
Mohinder Pal Garg1*, Ajai Jain2and Gian Bhushan3
1*
M.M.E.C. Mullana, Haryana, India, 133203, [email protected]
N.I.T., Kurukshetra, Haryana, India, 136118, [email protected]
3
N.I.T., Kurukshetra, Haryana, India, 136118,[email protected]
2
Wire electric discharge machining is one of the important non conventional machining processes which is
used in machining of difficulty to machine materials into intricate shapes. Present work investigates the
effectiveness of wire electric discharge machining in machining of Titanium 6-2-4-2 alloy. Experiments are
planned and analyzed using Box Behnken designs. Empirical model is developed for cutting rate using
regression analysis and is utilized for optimization of objective function. Confirmatory experiments are
carried to check the validity of optimization results. Further, surface topography of the machined samples is
analyzed using Scanning Electron Microscopy.
Keywords:WEDM, Box-Behnken Designs, Ti 6-2-4-2, SEM
Abstracts of Advanced
Manufacturing-II (Laser Based
Manufacturing) Papers
A Simple Analytical Model of Laser Bending
A. Eideh1, U.S. Dixit2 and Raghu Echempati3*
1
Department of Mechanical Engineering, Indian Institute of Technology Guwahati–781 039
2
3*
Department of Mechanical Engineering, Kettering University, Flint, MI, USA– 48504
Laser bending is a process of bending a sheet by the irradiation of laser beam on the surface of the sheet. A
number of analytical and numerical methods have been proposed for the estimation of bend angle. A brief
review of these methods is presented. A finite element analysis to simulate the laser bending process is carried
out with ABAQUS package for the purpose of understanding the physics of this process. Afterwards, a simple
analytical model is developed to evaluate the bending angle in laser bending of metal sheet. The model is
based on bending of sheet using the elastic-plastic theory. It is ascertained from the experimental results
available in literature that the results from the proposed model provide reasonably good prediction of bend
angle. It is also shown that the model can be used for the quick estimation of yield stress of the material during
laser bending process.
Keyword: Laser bending, Finite element method, Temperature distribution
Development of a Mathematical Formulation for the Development of Compound Curve
Surface by Laser Line Heating
Biplab Das1 and Pankaj Biswas2
Mechanical Engineering, IIT Guwahati, India-781039,
2
Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Pin 781039,
1
Line heating assisted with laser as a heat source is a flexible forming process that forms sheet metal by
means of stresses induced by external heat instead of by means of external force. The process has the
potential to be applied as a primary forming method for forming accurate shapes. However successful
application of this process in industry is limited due to high equipment costs and safety requirements. The
production of complex shapes requires the understanding of laser-material interaction. The paper presents
the mathematical formulation of development of smooth continuous curved surface. It is developed by
deformation of sheet under plane stress condition by taking into account the strain distribution and the
coefficient of first fundamental form of curve surface. Surface development is carried out along principal
curvature direction along with the procedure for suitable determination of heating line pattern for the desired
engineering surfaces.
Keywords :Line heating, Strain field, Doubly curve surface, Scanning path.
Effect of process parameters on thermal history of laser welding of AISI-304 stainless
steel
Rakesh Bhadra1, Pankaj Biswas2 and M. Ravi Sankar3
Mechanical Engineering, IIT Guwahati, India-781039
Email: [email protected], [email protected] [email protected]
Laser welding is a high precision, sophisticated and high speed joining process. It is a process of joining
plate where laser beam used as a heat source. In this present study a 3-DFinite Element (FE) model has been
developed for finding out transient thermal analysis of Laser Welding of AISI-304 stainless steel.The
transient thermal histories were predicted taking into account the temperature dependent material properties.
The temperature distribution predicted by the numerical model developed in the present work compared
fairly well with those of the experimental results / published literatures. After validation, the same model
has been used to study the effect of different laser welding process parameters on thermal history of AISI304 stainless steel. It has been observed that welding process parameters have significant effect on thermal
history.
Keywords: Finite element method, laser welding, process parameters, transient thermal history, temperature
dependent material properties.
A literature review on CO2 laser welding
Rakesh Bhadra1, Pankaj Biswas2 and M. Ravi Sankar3
Mechanical Engineering, IIT Guwahati, India-781039,
1
Email: [email protected], [email protected] ,[email protected]
Laser welding is a high precision, sophisticated and high speed joining process. Laser welding is a process
of joining plate where laser beam used as a heat source. In this present study an overall literature review on
welding by laser as a heat source have been addressed. In the present review, emphasis has been given
especially on the laser welding numerical and experimental temperature field analysis, thermo-mechanical
analysis. The time frame of the review is up to the year 2013.
Keywords: Laser welding, numerical and experiment temperature distribution, deformation, microstructure.
A 3-D Finite Element Analysis of Transient Temperature Profile of Laser Welded Ti6al-4v Alloy
Chandan kumar1, Manas Das2*and Pankaj Biswas3
1
2
3
In this work a numerical investigation of transient temperature profile of laser beam welding process is
carried out. A 3-D finite element modelling is developed considering combined double-ellipsoidal heat
source model for both spot and moving heat source. The temperature dependent thermo-physical material
property of Ti-6Al-4V alloy is incorporated. The effect of latent heat of fusion and convective and radiative
boundary conditions are considered. The effect of laser beam power on the transient temperature profile and
the dimensions of the heat affected zone are analysed. From finite element simulation, it is observed that the
peak temperature in the fusion zone increases with increased beam power. Also, the size of the heat affected
zone strongly depends on the power of the laser beam.
Keywords: Laser beam welding, Power density, Titanium alloy, Thermal analysis
Nd:YAG laser microdrilling of SiC-30BN nanocomposite: Experimental study and
process optimization
Roy. N.1*, Kuar. A. S.2, Mitra, S.3 and Acherjee, B.4
1*Department of Production Engineering, Jadavpur University, Kolkata, India,700032,Email:
[email protected]
2 Department of Production Engineering, Jadavpur University, Kolkata, India,700032,Email:
[email protected]
3 Department of Production Engineering, Jadavpur University, Kolkata, India,700032,Email:
[email protected]
4 Department of Production Engineering, BIT Mesra, Extension Centre, Deoghar 815 142, India ,Email:
[email protected]
Nd: YAG laser microdrilling of SiC30BN nanocomposite material is studied here. Taguchi based grey
relational analysis is used to simultaneously determine the optimum setting for minimum hole taper and
HAZ width. Grey relation analysis is adopted for combining multiple quality characteristics into one
integrated numerical value called Grey relational grade. A L27 orthogonal array has been used for
conducting experiments. Lamp current, pulse frequency, pulse width, assist gas pressure and focal distance
are considered as input process parameters whereas hole taper and HAZ width are considered as machining
responses. It is observed that the quality characteristics of drilled micro holes are improved markedly at the
optimized parameter settings as compared to quality levels achieved for initial machine parameter settings.
Keywords: Nanocomposite, Hole taper, HAZ Width, Grey Relational Analysis.
Experimental Studies on Fibre Laser Micro-Machining of Ti-6Al-4V
A. Sen1*, B. Doloi2 andB.Bhattacharyya3
Production Engineering Department, Jadavpur University, Kolkata, India, 700032,
2
production Engineering Department, Jadavpur University, Kolkata, India, 700032,
3
production Engineering Department, Jadavpur University, Kolkata, India, 700032,
1*
Titanium alloy plays a significant role in the advancement of engineering in the area of advanced structures
and technologies for aerospace and power industry, medicine, automatics and mechatronics, and
measurement equipment, owing to its unique combination of physical, chemical and mechanical such as
high strength and stiffness at elevated temperatures , high corrosion resistance, fatigue resistance, high
strength to weight ratio and ability to withstand moderately high temperatures without creeping. The
conventional cutting methods not only face difficulties for cutting these alloys due to their poor thermal
conductivity, low elastic modulus and high chemical affinity at elevated temperaturesbut also undergo from
higher cost associated with the machining of Ti-6Al-4V caused by lower cutting speeds and shorter tool
life.The application of micro-grooves on Ti-6Al-4V predominantly lies in the biomedical devices and the
implantation into the bone which further needs to be integrated with the surround tissue for the bone
healing.The aim of the present research work is to investigate the fibre laser ablated micro-grooves on Ti6Al-4V of 1.1 mm thickness in atmospheric condition with different parametric combinations and also to
find out the parametric effects on the groove geometry in terms of width, depth, and surface roughness.To
understand the parametric effect of the geometry of the micro-grooves, various ranges of process parameters
were considered for the experimental analysis such as (a) No of passes of 1 to 8; (b) scan speed of 40
to1000 mm/sec; (c) Pulse frequency of 50 to 100 kHz; (d) average power of 2.5 to30W. Groove geometries
were measured using optical microscope and the surface roughness was measured using AFM (atomic force
microscope).
Keywords: Fibre laser, Micro-groove, Ti-6Al-4V.
Effect of Different Surface Coatings on Laser Forming of Mild Steel Sheets
Sunil K. Singh1, Sachin S. Gautam2* and Uday S. Dixit3
Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Guwahati, 781039 India EMail: [email protected], 2*[email protected], [email protected]
In the present work, the effect of different surface coatings, namely lime and cement, on laser forming of mild
steel sheets is studied. The performance of the coatings is evaluated at different values of laser power and scan
speed. It is found that the cement coating leads to higher deformation. This means that in case of line heating
of sheets cement coating leads to higher bend angles. For other complex shapes for e.g. bowl or dome it leads
to higher heights.
Keywords: Sheet Metal, Laser forming, Bending, Coating
Numerical Investigation and Statistical Analysis of Laser Bending of Titanium Sheets
K.Paramasivan1*, Sandip Das1, Dipten Misra1, M. Sundar2
School of Laser Science & Engineering, Jadavpur University, Kolkata-700032,
1
School of Laser Science & Engineering, Jadavpur University, Kolkata-700032,
1
School of Laser Science & Engineering, Jadavpur University, Kolkata-700032, Email: [email protected]
2
School of Mechanical and Manufacturing, Loughborough University, Loughborough, Leicestershire,
LE113TUUK, UK, Email: [email protected]
1*
This paper presents a numerical investigation and statistical analysis of laser bending of Titanium sheets.
The aim of the present simulation is to identify the response through response surface methodology related
to bending angle and characterize the effects of input parameters: laser power, spot diameter, scanning
speed and plate thickness. The numerical simulations are carried out based on the four factors, central
composite face centered design. The statistical software Design-Expert® is used to create the design layout
and to obtain the final regression equation. The numerical simulation is carried out by implementing a
Gaussian surface heat flux, and convection–radiation boundary conditions through commercial finite
element software COMSOL MULTIPHYSICS. Investigations reveal that bending angle increases with laser
power and decreases with the increase in scanning speed, spot diameter and plate thickness. The optimum
process parameters for the target bending angle are also found based on misimisation of processing time and
operating energy.
Keywords: Numerical investigation, Statistical analysis, Laser bending
Effect of Pulsed Nd:YAG Laser Parameters in Preplaced TiC Coating on Aluminium
Substrate
Chinmaya Kumar Sahoo1, Jageshwar Kumar Sahu2andManoj Masanta3*
1
Dept of Mechanical Engg., NIT Rourkela, Rourkela – 769 008, INDIA,
2
3*
A Pulsed Nd:YAG laser was used for study of TiC coating on pure aluminium substrate. Effect of laser peak
power and pulse overlapping on the aluminium substrate by preplacing TiC powder was observed
experimentally. Optical images of the cross-sectional view of the laser irradiated samples show successful
formation of coating. Experimental results show that increasing laser peak power and pulse overlapping
increases the coating thickness. High peak power results removal of coating material but formed a TiC
mixed Aluminium zone. Micro-hardness profile on the coating shows improvement in hardness more than
20 times of Aluminium substrate.
Keywords: Pulsed Nd:YAG laser, TiC coating, Aluminium, Laser Surface Coating
Comparative Study of Surface Roughness Criteria During Pulsed Nd:YAG Laser
Micro-Turning of Alumina Ceramic at Laser Focused and Defocused Conditions
G. Kibria1*, B. Doloi2 and B. Bhattacharyya3
Department of Mechanical Engineering, Aliah University, Kolkata-700091, India, E-mail:
[email protected]
2
Department of Production Engineering, Jadavpur University, Kolkata-700032, India, E-mail:
[email protected]
3
Department of Production Engineering, Jadavpur University, Kolkata-700032, India, E-mail:
[email protected]
1*
Laser micromachining technology finds great potentials for successful application in the area of high
precision micro-engineering. Laser micro-turning process is one of the new and emerging technologies in
the area of laser material processing (LMP) of engineering materials. Laser micro-turning process is one of
the latest promising laser material processing techniques which can be employed for generation of microturning surface of particular surface profile and dimensional accuracy on cylindrical workpiece. The present
paper addresses the laser micro-turning process of cylindrical shaped 99% pure aluminium oxide (Al2O3)
ceramics of size 10 mm in diameter and 40 mm in length. The experiments have been conducted utilizing
one factor at a time (OFAT) experimental scheme. The targated depth was set at 100 µm. Laser average
power, pulse frequency, workpiece rotating speed and Y feed rate were considered as process variables.
After each experiment, surface roughness (Ra and Rt) has been measured. An attempt has been made for
comparative study and analyse the effect of focused and defocused conditions of laser beam on surface
roughness criteria of laser micro-turning surface. From the experimental results, it was revealed that both
surface roughness, Ra and Rt, are less at all defocusing conditions of laser beam compared with focusing
condition of beam. However, other process parameters have significant effects on surface roughness criteria
at both the focused and defocused conditions. Optical and SEM micrographs of the laser turned surface have
also been studied comparatively to examine the quality of machined surface at various parametric settings
and focusing conditions.
Keywords: Laser micro-turning process, Alumina (Al2O3), Surface roughness, Focusing conditions
Study and Analysis of Thermal Effects during The Excimer Laser Ablation Of
Polymers In Different Gaseous Environment
James Jacob1, P. Shanmugavelu2, R.Balasubramaniam3 and Ramesh K.Singh4
1,2,3
Bhabha Atomic Research Centre, Mumbai, India-400 085,
4
Indian Institute of Technology, Mumbai.
1*
[email protected]; [email protected]
2
[email protected];
3
[email protected]
4
[email protected]
Non-conventional, non-contact type advanced machining process like laser based micro machining process
is widely used in modern industries for producing components with geometrically complex profiles. Though
laser based micro machining of polymer, by and large, is a cold ablation process, photo thermal process
associated with the laser heating may affect the surface characteristics. The present study was conducted to
ascertain the impact of purging with gases such as air, argon, nitrogen, helium and hydrogen during the laser
ablation process. A negative photo resist, E-1020 obtained from M/s Cadmosil Chemical Pvt.Ltd, India was
studied using 248 nm KrFExcimer laser. The effect of gas purging on the ablation rate and surface
characteristics of the polymer was studied. Amongst the gases used, hydrogen gas showed distinct results
with respect to ablation rate and surface characteristics. It has been observed that hydrogen gas has
enhanced both the ablation rate and the surface quality significantly. The role of hydrogen gas in enhancing
the laser ablation rate may be attributed to the possible involvement of hydrogen gas in the laser assisted
chemical reaction (LACR) with polymer. Similarly, the improved surface characteristic might be due to
effective cooling property of hydrogen gas owing to its higher thermal conductivity. In this paper, the details
of the experiment along with the results and observations, with areas for future study have been presented.
Keywords: Laser micromachining, Excimer laser, Photo resist, Assist gas.
Studies on CO2 laser micromachining on PMMA to fabricate micro channel for
microfluidic applications
Rishi Kant1,2, *, Ankur Gupta1,2 and S. Bhattacharya1,2
Microsystems fabrication laboratory, IIT Kanpur - 208016,
2
Mechanical Engineering Department, IIT Kanpur - 208016,
*
[email protected], [email protected], [email protected]
1
Microfluidic devices are in great demand in the field of biomedical technology, point of care diagnostics
and chemical analysis. The rapid and low cost manufacturing of these devices have been a challenge. CO2
laser micromachining plays an important role in machining although it renders the machined surfaces with
high roughness. This study is an attempt to do process optimization of laser micromachining technique
which may produce smooth machined surfaces. Herein, the impact of process parameters like raster speed
,laser power, print resolution etc. are optimized using two target functions of dimensional precision and
surface roughness on microchannels made in PMMA (Poly methyl metha acrylate) substrates. The laser
machined PMMA samples are analyzed using 3D- profilometry and Field emission scanning electron
microscope (FESEM) for surface quality and dimensional precision. To investigate optimum process
parameters of CO2 laser for fabricating the microchannel on PMMA with dimensional accuracy and good
surface quality, Analysis of variance (ANOVA) and regression analyses is conducted. It is found that
optimum surface roughness of this process is around 7.1 µm at the optimum values of the process
parameters 7.5 mm /sec (50% of maximum machine limit) raster speed, 17.9 Watt (51% of maximum
machine limit) laser power and 1200 DPI (100% of maximum machine limit) printing resolution. The static
contact angle of the micro-machined surface has also been observed for analyzing the amenability of these
channels to flow of water like fluids for micro-fluidic applications.
Keywords: PMMA, CO2 laser, micromachining, contact angle
Fabrication of Micro Lens Array by Excimer Laser Micromachining
Syed Nadeem Akhtar1*, Shashank Sharma2 and J. Ramkumar3
*Dept. of Mechanical Engineering, Indian Institute of Technology Kanpur, Kanpur, India, 208016,
[email protected]
2
Dept. of Mechanical Engineering, Indian Institute of Information Technology, Design and Manufacturing,
Jabalpur, India, 482005, [email protected]
3
Dept. of Mechanical Engineering, Indian Institute of Technology Kanpur, Kanpur, India, 208016,
[email protected]
1
Micro lens arrays are widely used in optical devices such as photo-sensors, digital projectors, photovoltaic
cells, 3D imaging etc. These have traditionally been fabricated by photolithography, moulding and
embossing, reactive ion etching and electroforming. These processes are wet processes and require
expensive setup and running cost. A novel method is presented in this work that allows fabrication of micro
lens array using excimer laser micromachining. The fabrication has been done using mask projection with
work piece scanning. A KrFexcimer laser has been used to micro machine lenses on a poly(methyl
methacrylate) substrate. The surface profile of the lens array is measured and then related to the lasermaterial coupling and the energy of the laser pulses. Using this method, it is possible to fabricate micro
lenses down to a diameter of 5 µm over a considerably large area.
Keywords: Excimer laser, Lens array, Ablation rate, Micro machining
Studies on laser-sintering of copper by direct metal laser sintering process
Vinod A.R.1and Srinivasa C.K.2
1*
Central Manufacturing Technology Institute,Tumkur road, Bangalore-560 022,
2
Central Manufacturing Technology Institute, Tumkur road, Bangalore-560 022,
Direct metal laser sintering (DMLS) is one of the popularadditive manufacturing (AM) technologies for
fabrication of metal parts directly from CAD data. In the present study, copper-based parts were built using
DMLS process after blending of copper and bronze-nickel powders. Blending was carried out in a double
cone blending machine to obtain a homogeneous mixture of Cu - 5, 10 and 15 wt.% Nickel powders. Lasersintering of blended powders was carried out using DMLS process. Laser scan speed was varied from 200 to
500 mm/s in steps of 100, while laser power, layer thickness, hatch width and hatch spacing were
maintained constant at 240 W, 0.06 mm, 5 mm and 0.2 mm respectively. Laser scan speed had a significant
effect on the density and dimensional accuracy of the sintered parts.
Keywords: Additive manufacturing, DMLS, Copper, Electrodes.
Experimental Study on Micromachining of 304 Stainless Steel Under Water Using
Pulsed Nd:YAG Laser Beam
RasmiRanjan Behera1, Mamilla Ravi Sankar1*, Indrajeet Kumar2, Ashwini Kumar Sharma2, Alika
Khare2 and J. Swaminathan3
1*
Department of Mechanical Engineering, IIT Guwahati, Guwahati -781039, India
2
Department of Physics,IIT Guwahati, Guwahati -781039, India
3
National Metallurgical Laboratory, Jamshedpur-831007, India
1
[email protected], 1*[email protected], [email protected], [email protected],
2
Fabrication of miniaturized components is the current subject of research and development, as the
applications of these products varies from industry to industry such as aerospace, biomedical, micro-electromechanical system (MEMS) etc. These components may include micro-holes, micro-channels, micronozzles etc. of size less than 500 m which are commonly found in various products such as biomedical
filters, high-pressure orifices, and fuel injection nozzles etc. It is very difficult to fabricate the microfeatures in large number using conventional machining processes due to high tool wear, high heat
generation, and change in material properties. Fabrication of such components provides a challenge to the
manufacturing industries and to meet the challenges many unconventional machining methods are
developed, among which Laser Beam Micromachining (LBµM) is one of them. The main advantages of
LBµM are no tool wear, ability to machine complex shapes, high precision, high energy density and less
machining time. But defects like recast layer, heat affected zone (HAZ), crack, debris etc. are obtained
during laser beam machining in air due to high thermal gradients. Under liquid laser beam machining
reduces the temperature gradient, bulges, HAZ and splashing of molten material in order to achieve crackfree machined micro-parts with high ablation rate. In this research work, under water LBµM is carried out
using Nd:YAG laser for achieving high quality microchannels on 304 stainless steel. Water layer thickness
andscanningspeed are used as the process parameters where as kerf width, kerf depth and surface roughness
are used as the microchannel characteristics. Optical microscope and Scanning electron microscope were
used to measure and analyze the microchannel characteristics.
Keywords: Microchannel, Nd:YAG laser, recast layer, HAZ
Improvement of Corrosion Resistance by Laser Surface Melting of 7075 Aluminum
Alloy
A.C.Umamaheshwer Rao1*, V.Vasu2, S.M. Shariff3and K.V. Sai Srinadh4
Department of Mechanical Engineering, National Institute of Technology Warangal, Warangal, India,
2
Department of Mechanical Engineering, National Institute of Technology Warangal,Warangal, India,
3
International Advanced Research Centre for Powder Metallurgy and New Materials (ARCI), Hyderabad
4
Department of Mechanical Engineering, National Institute of Technology Warangal, Warangal, India,
1*
In the present work, a high power diode laser (HPDL) has been used for surface melting of a 7075-T651
aluminum alloy under a nitrogen atmosphere to induce microstructural changes on the surface to improve
corrosion resistance. The re-solidified laser-melted layer got refined with elimination of detrimental
constituent particles and grain boundary network present in wrought structure. The compositional and
microstructural analysis of the laser melted layer carried out by SEM, XRD and EDS indicated complete
absence of coarse precipitates. The comparative corrosion study determined by Potentiodynamic
Polarization measurements in 3.5 % sodium chloride solution showed corrosion current reduced by 5 times
in laser melted surface compared to un-treated substrate. The refined microstructure of laser melted layer
with presence of aluminum nitride phase, that can plausibly enhance electrical insulation, could be attributed
to its vast improvement in corrosion resistance.
Keywords: Aluminum 7075, Laser surface melting, Corrosion
Finite Element Analysis on Pulsed Laser Forming of Sheet Metal
Kuntal Maji1, D. K. Pratihar2*, A. K. Nath3
1,2,3
Indian Institute of Technology, Kharagpur
Kharagpur-721 302, India
E-mail: [email protected], 2*[email protected], [email protected]
Pulsed laser forming is a non-contact thermal forming process, where sheet metal gets plastically deformed
by thermal residual stresses induced by controlled discontinuous laser irradiations. The aim of this paper is
to determine the temperature and deformation fields using finite element analysis under different processing
conditions. Two types of pulsed laser forming processes, i.e., overlapped and discrete spot forming have
been identified depending on the combinations of process parameters. Bending angle is found to increase
with the degree of overlap and decrease with the increase of gap in case of the two types of spot forming
processes. A comparative study between pulsed and continuous laser forming has also been performed using
both finite element simulation and experiments. Bending angle in case of discrete spot pulsed laser forming
is found to be more compared to the continuous laser forming. The results of finite element simulations have
been found to be in good agreement with the experimental results.
Keywords: pulsed laser forming, Finite element analysis, Experimental study
Modeling and Optimization on Nd: YAG Laser Marking of Zirconia Ceramic using
RSM and ANN
Josephine Peter*, B. Doloi and B. Bhattacharyya
Production Engineering Department, Jadavpur University, Kolkata-700032, India
Laser marking is one of the well-developed technologies of materials processing. Laser marking is the best
and most applied permanent marking method. The present research papers deals with the artificial neural
network (ANN) and the response surface methodology (RSM) based mathematical modelling and also an
optimization analysis on marking characteristics i.e., mark width, mark depth and mark intensity on zirconia
ceramic. The major influencing laser marking process parameter considered are pulse frequency, lamp
current, pulse width, scanning speed and air pressure. The experiments have been planned and carried out
based on RSM based modelling with 32 runs. ANN modelling is performed and the results are compared.
The average percentage of prediction errors of the developed ANN model for mark width, mark depth and
mark intensity are 2.52, 2.58 and 2.58 respectively and the overall percentage of prediction error is 2.6. The
output of the RSM optimal data is validated through experimentation and ANN predictive model. A good
agreement is observed between the results based on ANN predictive model of 82.8 m, 46.3 m and 0.605
for mark width, mark depth and mark intensity respectively and actual experimental observations.
Keywords: Laser marking, Zirconia, RSM and ANN
Thermo-Mechanical Modelling of Laser Cladding of CPM9V on H13 Tool Steel
Santanu Paul1*, Ramesh Singh2and Wenyi Yan3
IIT B-Monash Research Academy, Mumbai, 400076, Email: [email protected]
2
Indian Institute of Technology, Mumbai, 400076, Email: [email protected]
3
Monash University, Clayton VIC3800, Australia, Email: [email protected]
1*
Laser cladding is a coating technique, wherein several layers of clad materials are deposited over a substrate
so as to enhance the physical properties of the work-piece such as wear resistance, corrosion resistance etc.
Strong interfacial bond with minimum dilution between the material layers is a pre-requisite of the process.
This technique also finds widespread applications in repair and restoration of aerospace, naval, automobile
components.A thermo-mechanical finite element model is developed wherein the Gaussian moving heat
source is modelled along with element birth and death technique to simulate powder injection laser cladding
of CPM9V over H13 tool steel which is extensively used for repair of dies. The present work is focuses on
predicting the clad geometry and other clad characteristics such as the heat affected zone, dilution region
and the subsequent residual stress evolution. It is expected that this knowledge can be used for repair of
structures subjected to cyclic thermo-mechanical loads.
Keywords: Finite element model, Gaussian moving heat source, Element birth technique
Experimental Investigations on CO2 Laser Micro Texturing on Near-Titanium Alloy
(IMI 834)
M. Ravi Sankar1*, S. Tarun Kumar1, Kishor Kumar Gajrani1, J. Swaminathan2 and U. S. Dixit1
1*
Department of Mechanical Engineering, IIT Guwahati, Guwahati -781039, India
2
National Metallurgical Laboratory, Jamshedpur-831007, India
1*
Email: [email protected], Email: [email protected], 2 Email: [email protected],
1
Due to superior mechanical properties of titanium alloy at elevated temperature like high thermal
conductivity, low thermal expansion, low density, wear and corrosion resistance; they are widely used in
aircraft industries, automobile industries, electrical industries, etc. Laser surface texturing (LST) was
performed on the titanium alloy (IMI 834) by a CO2 laser and different sizes of dimples were created by
varying input process parameters. In order to improve practical laser surface texturing process for titanium
based alloys, an understanding of process involved in laser machining is necessary. This study is carried out
to understand the effect of different input process parameters (laser power, focus position and duty cycle)
over the texture diameter. Optical microscopy and scanning electron microscopy (SEM) was used for
measuring and analyzing of texture quality.
Keywords: CO2 laser, LST, Micro-texturing, Titanium alloy, SEM.
Finite Element Simulations of Laser Bending of Small Sized Sheets
Besufekad, N. Fetene1* and Uday, S. Dixit2
2
1*
Recently, laser bending has received attention for a wide variety of applications in industries due to its
excellent bend quality with high productivity and flexibility. In this work, finite element simulations of
bending of small sized sheets are carried out using ABAQUS package. The temperature and strain-rate
dependent material properties of D36 shipbuilding steel sheet are considered. Simulation results throw light
on the bending behavior of small sized sheet components.
Keywords: Laser bending, Stationary heat source, Moving heat source, FEM
Surface Alloying of Aluminum with Copper Using Co2 Laser
Woldetinsay G. Jiru1*, Mamilla R. Sankar2 and Uday S. Dixit3
Department of Mechanical Engineering, Indian Institute of Technology Guwahati–781 039
Emails: 1*[email protected], [email protected], [email protected]
Aluminium and its alloys have high demand in industries and service applications due to their light weight
compared to their strength when alloyed with different metals like Cu, Mg, Ni, Cr, Zn and others for
enhanced longer service life. In this work, commercially available 99% pure aluminium was alloyed with
copper powder of 10µm particles size, which was melted by CO2 laser. Three different methods were used
for uniform placing of95% copper powder and 5% aluminium powder on aluminiumsubstrate. The result
was examined by Vickers hardness test. SEM and FESEM were used for studying surface and subsurface
defects. Defect free aluminium alloy with improved microstructure and enhanced mechanical property was
achieved.
Keywords: Surface alloying, CO2 laser, Copper powder, Aluminium alloy
Energy Based Analysis of Laser Microchanneling Process on Polymethyl Methacrylate
(PMMA)
Shashi Prakash1* and Subrata Kumar2
1
Mechanical Engineering Department, Indian Institute of Technology Patna, Patna, India,
2
Mechanical Engineering Department Indian Institute of Technology Patna, Patna, India,
CO2 laser micromachining provides low cost machining solution for fabrication of three dimensional
microfluidic channels. In this research work CO2 laser microchanneling has been analyzed from the first
principle. The material properties like absorptivity and thermal properties have been investigated.
Simultaneous TGA/DSC test have been conducted to determine various thermal properties of PMMA.
Considering the Gaussian distribution of laser beam, an energy model has been proposed to predict the
microchannel depth and channel profile. Since thermal conductivity of the PMMA is very low, the
conduction loss has been neglected. The proposed model successfully predicts the channel depth and profile
without much loss of accuracy. Experiments have been performed on a 3 mm thick PMMA sheet and actual
and predicted results have been compared. Energy based analysis is found to be simple yet powerful method
to predict the channel dimensions for low thermal conductivity materials.
Keywords: CO2 laser beam machining, PMMA, Microchanneling, Energy analysis
Experimental Investigation on Laser Bending of Metal Sheets Using Parabolic
Irradiations
Parag M. Bhuyan1, Ravi Kant2, S.N. Joshi3,*
1
Engineering Research Center, Tata Motors Ltd., Pune, Maharashtra - 411018, India
2
Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Assam-781039, India,
3
Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Assam-781039, India,
This paper presents a study on the bending behavior of aluminum sheets during parabolic laser irradiations.
Effects of input parameters such as, laser power, scanning speed, sheet thickness and path curvature on bend
angle are studied for temperature gradient mechanism (TGM) and buckling mechanism (BM) dominated
process conditions. Results showed that the input parameters have non-linear effects on bend angle. The
effect of input parameters was found to be different for TGM and BM dominated process conditions. It was
observed that for thick sheets, increase in scanning path curvature significantly decreases the bend angle.
The deformation behavior of curvilinear laser bending process is different from straight line laser bending. It
was observed that in curvilinear laser bending, the workpiece bend outside of the scanning path curvature.
Keywords: Laser bending, Curvilinear irradiation, Bend angle, Path curvature
An Experimental Investigation on Fiber Laser Welding at Controlled Inert Gas
Atmosphere
Yadaiah Nirsanametla1*, Swarup Bag1, C. P. Paul2 and L. M. Kukreja2
Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Guwahati, Assam
781039, India.
E-Mail: [email protected]*; [email protected]
2
Laser Material Processing Division, Raja Ramanna Centre for Advanced Technology, Indore, Madhya
Pradesh 452013, India.
E-Mail: [email protected], [email protected]
1
Fiber laser is a desirable heat source for deep-penetration and high-speed fusion welding process due to its
noticeable advantages such as high beam quality and high efficiency over other lasers. During fusion
welding process, thermo-chemical reactions may take place among surrounding atmosphere particles and
molten weld pool at high temperature gradients. The atmosphere particles such as oxygen, hydrogen and
nitrogen may become part of final weld joint that severely affects the weld joint quality and weld metal
properties. Therefore, the welding atmosphere and protection of weld pool plays a noticeable role on the
quality of the final weld joint. Henceforth, in the present work, fiber laser welding of austenitic stainless
steel have been investigated in two different ambient atmospheres. Firstly, the experiments are conducted in
open atmosphere and in argon ambient atmosphere to study the characteristic difference on weld joint with
respect to weld bead size and dimensions, and microstructure formation at different welding speeds. The
experimental investigation specifies that the weld bead dimensions are higher in case of argon atmosphere
as compared to open atmosphere. The microstructures of heat affected zone (HAZ) and fusion zone (FZ) at
both atmospheric conditions are analyzed. It is also obvious from the experimental results that the top
surface profile is better and weld surface is very clear in case of welds at argon atmosphere as compared to
open atmospheric condition.
Keywords: Fiber laser, fusion welding, Inert gas atmosphere, Open atmosphere, Metallographic analysis
Fabrication of Micro-Channels on Mild Steel Using Laser Induced Micro-Machining
Sanasam Sunderlal Singh1, Kh. Shantakumar2, Alika Khare2 and S.N. Joshi1*
Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Guwahati -781 039,
Assam, INDIA
2
Department of Physics, Indian Institute of Technology Guwahati, Guwahati -781 039, Assam, INDIA
*Corresponding author: email: [email protected]
1
Laser Induced Micro-machining (LIMM) uses a focused high power laser beam to remove volume of
material by using the phenomenon of ablation. In comparison with mechanical micro-machining operations,
it offers better machining efficiency in terms of accurate work or feature geometry, efficient debris removal,
and better surface morphology. This is due to the fact that laser can be very precisely focused onto the work
piece and results into the removal of material from the focal volume only. In this present work, an
experimental study on manufacturing of micro-channels of width 150 µm on mild steel, by focusing the
second harmonic of a high power Q-switched Nd:YAG laser, has been presented. Initially two sets of
experiments have been carried out by varying the scan speed of the sample. The laser energy was kept
constant in both the cases. The work specimen was characterized for dimensional accuracy and shape of the
channel generated. These preliminary results are encouraging to manufacture the micro-grating on mild steel
as an important component of micro fluidic applications.
Keywords: Laser induced micromachining, Micro fluidic, Micro-channels
Abstracts of Composite
Fabrication Papers
Hilltop
Ferry Ghat at Brahmaputra River
Effect of Double and Triple Particle Size Al2O3 Reinforcement on Properties of
Aluminium Matrix Composite Prepared by Vacuum Moulding
Rupinder Singh1*, Sunpreet Singh2 and Kanwalpreet Sahni3
1*
GNDEC, Ludhiana, 141006,
*
)[email protected]
2
*
)[email protected]
3
The aim is to study the tribological behaviour of dual particle size (DPS) and triple particle size (TPS) of
Al2O3 reinforced aluminium matrix composites (AMCs) prepared by stir casting in vacuum mould. The ABS
plastic based master pattern of the component (brake rotor, an automotive tribo component) has been
prepared by fused deposition modelling (FDM). The DPS and TPS composite consisting of two and three
different sizes of Al2O3reinforcement respectively have been prepared by stir casting in vacuum mould for
development of Al-MMC. The tribological test was carried out using a pin-on-disc type tribo-test machine
under dry sliding condition. The study highlights the effect of reinforcement in form of DPS and TPS on
tribological behaviour of Al-Al2O3AMCs. This study reveals that DPS based AMC exhibited better wear
resistance properties compared to TPS. It has been observed that when a composite is integrated with small
and intermediate Al2O3 reinforcement (which is known as DPS) within the composite could be an effective
method of optimizing the wear resistance properties of the developed material. This study provides an
alternative way to enhance the tribological behaviour of automotive tribo component. The study also
highlights the percentage contribution of different input process parameters (like: composition of Al-Al2O3,
vacuum moulding silica sand grain size, vacuum pressure and component volume) on wear properties of AlAl2O3MMCs.
Keywords:Aluminium Matrix Composite, Vacuum Moulding, Stir Casting, Particle Size
Investigations for Mechanical Properties of Metal Matrix Composite Prepared by
Combining FDM, Vacuum Moulding and Stir Casting
Rupinder Singh1*, Sunpreet Singh2 and Sardar Singh3
1*
Production Engg. Dept., GNDEC, Ludhiana, 141006,
2
3
There has been a critical need for development of aluminum (Al) based metal matrix composites (MMCs)
for various rapid tooling (RT) applications. But hither to no work has been reported on investigations for
mechanical properties of Al based MMC prepared by combining fused deposition modelling (FDM),
vacuum moulding (VM) and stir casting (SC) process. In the present work an approach to macro-model the
mechanical properties (like: surface roughness and dimensional accuracy) of Al based MMC prepared by
combining FDM, VM and SC process have been proposed and applied. The relationship between output
mechanical properties and other input parameters have been deduced by using Taguchi technique. For
optimum surface roughness the best settings were at 7.5% SiC mixed in Al, grain size of 70 AFS number
and vacuum pressure 0.05N/mm2 and for dimensional accuracy it was 5% SiC mixed in Al, grain size of 70
AFS number and vacuum pressure at 0.04 N/mm2+
Preparation and Tribological Characterization of Linear Low Density Poly-Ethylene
Sea Shell (LLDPE/Sea Shell) Bio Composite
GajendraMundel and M. Ravi Sankar*
Department of Mechanical Engineering, IIT Guwahati, Guwahati, 781039
[email protected],*[email protected]
In the current work, polymer bio-composite is fabricated using linear low density polyethylene (LLDPE) as
base polymer with varying weight percentage (wt%) of sea shell powder/particleas reinforcement. The
average sea shell particle size used in the work is about 75 µm.The reinforcement wt% varied
is5,10,20,30,and 40to check the various tribological properties. Pin-on-disc tribometer (Hardened AISI 4340
steel disc, abrasive disc) is used to check various tribological properties such as wear, frictional force and
average coefficient of friction. Apart from tribology, water absorption test of these compositions were
studied. Experimental results shows decrease of coefficient of friction and wear with increasing filler
content while water absorption behavior of composites increases as function of time of exposure studied
increased with increasing filler content.
Keywords: LLDPE, bio-composites, sea shells, tribology
Sisal Fiber / Glass Fiber Hybrid Nano Composite: The Tensile and Compressive
Properties
1*
Natarajan, N1*.Bharathidhasan, S2. ThanigaivelanandR3.Suresh, P4.
Department of Mechanical Engineering, Muthayammal College of Engineering, Rasipuram–637408,
Namakkal, Tamil Nadu, India.
Email)[email protected]
2
Department of Mechanical Engineering, Muthayammal College of
Engineering, Rasipuram–637408, Namakkal, Tamil Nadu, India.
3
Department of Mechanical Engineering, Muthayammal Engineering College,
Rasipuram–637408, Namakkal, Tamil Nadu, India
4
Department of Mechanical Engineering, Karpagam College of Engineering,
Coimbatore–641032, Tamil Nadu, India
Natural fiber reinforced polymer composites became more attractive due to their high specific strength, light
weight, and environmental concern.The incorporation of natural fibers such as sisal with glass fiber hybrid
composites has also gained increasing industrial applications. In this study natural and synthetic fibers are
combined in the same matrix (unsaturated polyester) to make Sisal/Glass fiber hybrid composites using
polyurethane resin. The fabrication of hybrid composite has been performed using hand lay-up method. The
fabricated hybrid composite has been tested and their mechanical properties are evaluated. Additionally sisal
nano fiber/glass fiber hybrid composite is fabricated by hand lay-up method and tested for comparing the
strength with sisal/glass fiber hybrid composite.
Keywords: Hybrid composite, Sisal fiber, Nano composite, Glass fiber
Dynamic Mechanical and Thermal Properties of Jute Nano Fibre Reinforced Polymer
Composite
K.T.B.Padal1*, S.Srikiran2 and P. Surya Nagendra3
1*
Department Mechanical Engineering, Andhra University, Visakhapatnam, 530 003,
2
Department of Mechanical Engineering, Kaushik College of Engineering, Visakhapatnam, 530052,
3
Department of Marine Engineering, Andhra University, Visakhapatnam, 530003,
A novel hybrid bio-composite is developed using bio-degradable Jute nanofibers reinforced in epoxy matrix.
Synthesis of the jute fibers was carried out using a high energy ball mill. The nanofibers used were of
particle sizes ranging from 10-30nm. The nano composites were processed using different weight
percentages 0-5 wt. % of jute nanofibers reinforced with epoxy polymer matrix by hand lay-up technique.
The mechanical and thermal properties of virgin (base) composite and nanocomposites (1-5wt.%) were
compared using Dynamic Mechanical Analysis (DMA), Thermo gravimetric Analysis (TGA) and
Differential Scanning Calorimetry (DSC), DMA results revealed that the storage modulus and loss modulus
of these nano composites was improved, where as the mechanical loss factor (tan delta) decreased. The
nanocomposites were subjected to the heating cycle between 30ºC-600ºC to obtain their thermal behavior
and TGA measured test were conducted in the temperature range of 30ºC- 300ºC to identify the thermal
transition of the nanocomposites. The reinforcement of jute nanofibers in composite improves the thermal
stability. This enhancement of the stability and properties can be attributed to an improvement in the
interfacial adhesion and compatibility between the nanofibers and matrix.
Keywords:Jute nanofibers, epoxy resin, Dynamic mechanical analysis, Thermogravomentric analysis.
Development and Tribological Performance of Nano Sic Particles on the AA2024
hybrid Composites with the Addition of Nano Graphite
S.Vinothkumar
1*
, K. Manisekar2 and P.Ravindran3
1* Department of Mechanical Engineering, National EngineeringCollege, Kovilpatti628503.Tamilnadu,India.
2Centrefor Manufacturing Sciences, National Engineering College, Kovilpatti628503. Tamilnadu,India.
3Department of Mechanical Engineering, St.MotherTheresa EngineeringCollege, Thoothukudi-628102,
Tamilnadu, India.
In this experimental study, hybrid nano composites of AA 2024 aluminum alloy matrix reinforced with high
weight fractions of nanometric SiC particles ranging from 5 to 10 wt % and 5% of Graphite particles were
produced byblend– press–sintermethodology. Consolidation was done at 700 MPa using uniaxial pressing.
Sintering procedure was done at 530 °C for 60 min. The mechanical properties of the sintered specimens
were evaluated by hardness and porosity measurements. The wear behavior of these composite materials
was investigated under dry sliding conditions. The sintered samples have been characterized by OM and
XRD. Wear mechanisms are discussed based on worn surface morphology and wear debris
morphology.The hardness and wear resistance of the hybrid nano composites were increased considerably
by increasing the reinforcement content. There results of the tests revealed that the SiC-reinforced hybrid
nano composites exhibited a lower wear loss compared to the unreinforced alloy and Al–Gr composites.
The nano composite with 5 wt. % Grand 10 wt. % SiC showed the greatest improvement in tribological
performance. It confirms that graphite particle was an effective solid lubricant for aluminium matrix
composite applied in dry sliding wear condition.
Keywords: Powder metallurgy, Mechanical milling,Wear, Hybrid nano composites.
Thermal Buckling of Temperature Dependent Functionally Graded Cylindrical Panel
1*
2
V. R. Kar and S. K. Panda
1*
Dept. of Mechanical Engg., NIT, Rourkela,769008,
2
Dept. of Mechanical Engg., NIT, Rourkela, 769008,
The buckling behaviour of functionally graded cylindrical panels under thermal loading is investigated in
this article. In functionally graded material, material properties vary smoothly from metal phase to ceramic
phase. In this study, the effective material properties of the functionally graded panels are considered as
temperature dependent and the gradation is taken in the transverse direction according to the power-law
distribution of volume fractions of eachconstituent.Thermal buckling behaviour of cylindrical panel has
been obtained numerically through ANSYS based on the ANSYS parametric design language code. The
model has been discretised using an eight node serendipity element with six degrees of freedom per node
(SHELL281) from the ANSYS library. The solutions are obtained by solving the eigenvalue type buckling
using Block Lanczos method. The accuracy of the model has been checked through corresponding
convergence and comparison study with those available literatures. Finally, the simulation model has been
extended to study the effect of different parameters such as power-law index, thickness ratio, curvature ratio
and aspect ratioon buckling strength for both temperature independent and dependent material properties of
each constituent.
Keywords: FGM,Thermal buckling, Finite element method,Temperature dependent
Fabrication and Study on Mechanical and Tribological Properties of Nano Al2O3 and
Micro B4c Particles-Reinforced A356 Hybridcomposites
Sukesha V1*, Rajeev Ranjan2 , G Nagesh3and K Sekar4
MED,NIT Calicut, 673601, Email:[email protected]
2
3
4
1*
Hybrid composites are advanced class of materials used for light weight application and having higher
strength and stiffness compared to other conventional materials. The automobile and aerospace industries
relenting passion to enhance the performance of commercial and military applications is constantly driving
the development of improved high performance structural materials.In the present study,Aluminium alloy
A356 matrix reinforced with nano Al2O3 [(APS 50nm,1 wt.%)] and micro B4C [(APS 100µm)0.5, 1, and
1.5 wt.%] were fabricated by combination of stir and squeeze casting method. The fabrication is performed
at a stirring speed of 300 rpm and 60 MPa pressure With Stirring time as 10 minutes. The microstructure
study such as optical microscope and SEM analysis revealed that uniform distribution Al2O3 and B4C
particles without agglomeration. The obtained composites were subjected to T6 heat treatment. The
mechanical properties such as Hardness Test, Compression Test and Density of both composites (Heat
treated and non-heat treated) were investigated. The results shows that the presence of nano-Al2O3 and
micro B4C particles with increase in wt.% in aluminium matrix led to significant improvement in the
mechanical properties of the composites compared to aluminium alloy and A356/Al2O3 composites. T6 heat
treated composites have good mechanical properties compared to without heat treated composites. This
enhancement in the mechanical properties is due to refinement of grain size and formation of globular
silicon particles. The effects of factors and interactions on the weight loss values of both composite and
counter materials were studied. Worn surfaces were studied using scanning electron microscope. The
densities of composites were increased and porosity is decreased due to squeezing effect
Keywords: A356/ Al2O3/ B4C composites, Heat treatment, Microstructure, Mechanical properties.
Hysteresis Heating of Polypropylene Based Composites
1
Ravi Shankar Shukla1, Johnney Mertens2 and S. Senthilvelan3*
Indian Institute of Technology, Guwahati, 0781039, [email protected]
2
3*
In the recent years, most of the machinery parts are being replaced by engineering plastics due to the light
weight and maintenance free characteristics. However one of the major challenge in utilizing these
thermoplastics and composites is to design the material against thermal induced fatigue failure. The major
source of heat generation of these materials during service is material hysteresis due to the visco elastic
characteristics in addition to the surface friction. In this work, polypropylene, glass fiber reinforced
polypropylene and carbon nano tube reinforced polypropylene materials are considered and subjected to
fatigue under displacement as well as load controlled mode. The net surface temperature of the specimen is
measured and monitored with the aid of non contactinfra red temperature sensor in addition to the
continuous measurement of load and displacement. In the position controlled mode, the amount of load
required to maintain same amount of deflection is continuously measured. Test specimens are also subjected
to load controlled mode and area of hysteresis at various cycles are measured. Hysteresis area of test
material conveys the internal heat generating capacity. From the investigation, it is confirmed glass fiber
reinforcement and carbon nano tube reinforcement improved material strength with reduced hysteretic
heating under fatigue condition.
Keywords: Nano composite, Hysteresis, Fatigue, Internal heating
Frictional Heat Generation in Selective Ceramic Reinforced Polymer Composites Effect of Particle Size
1
C. Gurunathan1*, R. Gnanamoorthy2 and S. Jayavel3
* IIITD&M Kancheepuram, Chennai, 600 127, [email protected]
2
IIITD&M Kancheepuram, Chennai, 600 127,[email protected]
3
IIITD&M Kancheepuram, Chennai, 600 127, [email protected]
Machine elements such as bushes, gear, and rollers made of polymer composites often fail by wear and/or
contact fatigue. During service, the temperature of contacting machine elements increases because of heat
generation due to friction and hysteresis and their properties degrade. The deterioration in the mechanical
properties of polymer due to the accumulation of heat near the contact region causes accelerated wear and
influence the performance of the parts. This research work focus on reducing the surface temperature and
increasing the wear resistance using selective ceramic reinforcement at the contact regions. This paper
describes a method to predict the temperature raise due to friction under sliding condition using simplified
numerical technique that will help in designing the surface reinforcement. The effect of particle size on the
surface temperature distribution in the selective ceramic reinforced polyamide 6 composites is reported. The
results reveal that the presence of ceramic particles at the contact region decreases the surface temperature
considerably. The reduction in surface temperature increases with the increase in percentage area coverage
by the particles. Presence of particles at the subsurface region enhances the heat transfer and effectively
reduces the surface temperature. For a given volume fraction of particle in matrix, significant reduction is
surface temperature can be achieved by placing large number of small size particles close to each other at
the contact surface and subsurface regions.
Keywords: Polymer composites, Surface reinforcement, Frictional heating, Surface temperature prediction.
Mechanical Behaviour of Jute Fibre Reinforced Polypropylene Composites
1, 2, 3
Temesgen Berhanu1*, Pradeep Kumar2 and Inderdeep Singh3
Mechanical and Industrial Engineering Department, IITR, Roorkee-247667, UK, India.
1*
[email protected], [email protected], [email protected]
Recently, Jute fibre is being used as a reinforcement material in the development of reinforced plastics for
various engineering applications. Its biodegradability, low cost, and moderate mechanical properties make it
a preferable reinforcement material in the development of polymer matrix composites. Therefore, Jute fibre
reinforced composites have replaced the most widely used synthetic fibre (glass, kevlar) reinforced
composites in many applications. In the present experimental endeavour, Jute fibre-polypropylene
reinforced composites were prepared using compression moulding process. The weight percentage of the
fibre reinforcement was varied as 30, 40 and 50%. The effect of the weight percentage of the Jute fibre
reinforcement was investigated experimentally on the mechanical properties of the developed composites.
The mechanical properties were tested using computerized UTM machine as per the ASTM standards.
Scanning Electron Microscope (SEM), X-ray Diffraction (XRD) and Thermal Analysis (TA) have been
utilized to fully understand the mechanical behaviour of developed composites. The results reveal that, the
mechanical properties of polypropylene based composites are substantially improved on account of the
addition of the Jute fibre reinforcement. It has also been observed that the significance of the enhancement
of the mechanical properties increased as the weight percentage of the Jute fibre reinforcement increased
up to 40%.
Keywords: Composites, Jute fibre, Mechanical Strength, SEM.
An Experimental Investigation OnpolymericNanocomposite Material
Panneerselvam K.1*and Jafrey Daniel2,
, Dept of Production Engg., NIT,Trichy 620015, Tamilnadu,India.
Email:[email protected] , [email protected]
1* 2
This research paper explains about the Manufacturing, mechanical characterization, and metallurgical
characterization of Polymeric composite. In this study two different types of composite material
(Polypropylene(PP) of grade REPOL H110MA as Matrix &Nanoclay of grade Cloisite®15A as
reinforcement and Polypropylene of grade REPOL H110MA as Matrix &Spheri glass 3000 as
reinforcement) were manufactured by using Twin screw extruder which ensures uniform mixing of
materials. The Mixed material has been casted to a shape as per the standard ISO: 527 by Injection molding
machine to carryout mechanical characterizations and metallurgical studies. The test specimen has been
manufactured for both Polypropylene with Nanoclay and Polypropylene with Spheri glass particle for
detailed investigations. The mechanical characterization has been performed with the help of an Electronic
Tensometer. From this result it has been observed that there is an improvement in the tensile strength of the
developed Nanocomposite of PP with 3% Nanoclay. Similarly PP with 7.25% of spheri glass particles has
shown better tensile properties. Metallurgical characterization like SEM analysis of NanoclaySpheri glass
particles reinforced with PP was also discussed in detail and presented in this paper.
Keywords: Polypropylene, Cloisite 15A,Spheri Glass 3000, Tensile Test.
Tribological performance of microwave sintered copper-CNT composites
1*
Rajkumar.K1* and Aravindan.S2
Department Mechanical Engineering, SSN college of Engineering, Kalavakkam, TN, India -603110
2
Department Mechanical Engineering, Indian Institute of Technology, New Delhi, India -110016
Microwave processing is a newer method to meet the demands of better properties, potentially at a lower
cost. Copper-carbon nano tube (CNT) composites are tribological composites that can be used in electrical
sliding contact applications. Copper- Copper-coated CNT (5-20 vol %) composites were fabricated through
powder metallurgy technique followed by microwave sintering process. Effects of CNT content and sliding
speed on the tribological performance (wear rate and co efficient of friction) of copper-CNT composites
under dry sliding condition were evaluated using a pin-on-disc apparatus. The characterization of the wornout layer of the composites was analyzed by scanning electron microscopical (SEM) studies.
Keywords: Copper, CNT, Wear, Electroless coating
Influence of Nano-Al2o3 and Micro-Zro2 Particles on Mechanical Property of A356
Based Composite Fabricated by Combination Effect of Stir And Squeeze Casting
Rajeev Ranjan1*,SukeshaV2, G.Nagesh3 and K Sekar4
Mechanical Egineering Department, NIT Calicut, 673601, Email:[email protected]
Aluminium Metal Composites(AMCs) is having better property compared to unreinforced materials like
greater strength,improved stiffness, reduced weight, improved properties at elevated temperature ,controlled
thermal expansion coefficientbehavior, enhanced electrical performance, improved abrasion and wear
resistance and improved damping capabilities.In the present work A356 has been casted with reinforcing
nano-Al2O3 and micro-ZrO2 ceramic powders. The reinforced powders is having high level of hardness and
toughness known as ceramic steel and having good strength at high temperature. Fabrication were done in a
resistance furnace equipped with stir and squeeze system. Furnace temperature was kept at 850˚C and
stirring was done at 300 rpm for 14 min.Ceramics were preheated at 600˚C for 30 min.A squeeze pressure
of 45MPa was applied in the semi solidstate.Samples were prepared for testings like hardness, double
shear,bending strength and for wear test.A short term heat treatment technique is applied for the heat
treatment of specimen (solution heat treatment at 560˚C for 2 hr and aging at 200˚C for 2 hr).For hardness
testBrinell hard test was used and4 indentations were done on each specimen to obtain data of hardness.
Heat treated specimen shows better mechanical property. Wear test was conducted on all the specimen,
ceramic reinforced specimen shows improved wear resistance. Worn surface morphology shows the
behavior of specimen at different loads and at different distances.
Keywords: AMC; Stir and Squeeze casting
Parametric Optimization of Al-Sic12% Metal Matrix Composite Machining by
Electrical Discharge Machine
Rajesh Kumar Bhuyan , B. C. Routara* , Arun Kumar Parida and A. K. Sahoo
School of Mechanical Engineering, KIIT University, Bhubaneswar, 751024
Email:[email protected],[email protected], [email protected] ,
[email protected]
In the present study, pure aluminium alloy is mixed with 12% SiC on weight basis to fabricate the metal
matrix composite (MMC) material. The objective of this paper is to investigate the effect of process
parameters such as pulse on time(Ton), peak current (Ip) and flushing pressure (Fp) on metal removal rate
(MRR), tool wear rate (TWR) and surface roughness (SR) during electrical discharge machining (EDM) of
Al-SiC12% MMC .The experiment is followed by Central composite design (CCD) method under different
combination of process parameters .In this paper Response surface methodology (RSM) is used to develop
the mathematical model and to correlate the process parameters with the response. Also Analysis of
Variance (ANOVA) technique is used to check the significance of the model and confirmation test is
conducted to compare the experimental data with the predicted data to identify the effectiveness of the
proposed method. From the main effective plot it is found that peak current is the most significant parameter
among the other. Further the morphology study of the composite is carried out by the Field emission
Scanning electron microscope (FESEM) of the surface after machining to make a relation with the model.
Keywords: Aluminium metal matrix composite, ANOVA, RSM, FESEM
Development and Characterization of Functionally Graded Materials Using Hybrid
Layered Manufacturing
Sajan Kapil1, Pravin M. Kulkarni2*, K. P. Karunakaran4 and Prathmesh Joshi3
1
Indian Institute of Technology Bombay, 400076, Email:[email protected]
2*
Indian Institute of Technology Bombay,400076, Email:[email protected]
3
4
A multi-layer functionally graded cast aluminium alloy is developed using Hybrid Layered Manufacturing
(HLM). The system hardware is composed of a 3-axis CNC machine integrated with a Gag metal Arc
Welding (GMAW) deposition unit.
Properties of the functionally graded materials were investigated both at macro and micro length-scales.
Realization of Functionally Gradient object is done by Directionally Heat Conductive (DHC) objects.
Direction dependent variations in microstructure were studied using Optical Microscopy. Mechanical
properties were tested using uni-axial tensile testing and micro-hardness indentation.
The microstructure showed a distinct variation along the layer thickness. Coarse microstructures were seen
towards the bottom layers whereas fine microstructures were found towards the top layers. Hardness
variations within a layer are explained with respect to the observed microstructure gradients. A significant
difference in heat conduction is observed in the two directions.
Keywords: Functionally Gradient Material, Gas Meta Arc Weld Deposition, Additive/ Subtractive/ Hybrid
Manufacturing, Directionally Heat Conductive Objects
Processing and Tensile Testing of 2024 Al Matrix Composite Reinforced with Al2O3
Nano-Particles
Kapil Kumar 1*, Dhirendra Verma 2 and Sudhir Kumar 3
1
Mechanical Engineering Department, NIET, Greater Noida-201306, UP, India
2
3
The fabrication of metal matrix nano composites (MMNCs) using mechanical stir casting process generally
results poor distribution of nano particles having high porosity in the matrix. To overcome the above
problems, mechanical stir casting was combined with electromagnetic stir casting process and formed
Hybrid Casting Process. Al 2024/1 % wt Al2O3nano composite was fabricated by injecting Al2O3
particulates into Al alloy with the assistance of argon gas. The wettability of the reinforcement was
enhanced by milling nano-SiC particles with micro Mg powder. The examination of composite was carried
out through Scanning Electron Microscopy (SEM), EDAX and tensile testing. SEM micrograph revealed
that the nano particles are fairly distributed in the matrix and also achieved the fine grain microstructure.
The tensile strength of Al2024/1 % wt Al2O3nano composite has improved by 43% as compare to the
Al2024 alloy.
Keywords: Hybrid stir casting, SEM, Tensile strength.
SynthesisAnd Machinability Studies of A356 Alloy-15% SiC Composite
K. Jayakumar1*, Jose Mathew2 and M. A. Joseph3
Dept of Mechanical Engineering, SSN College of Engineering, Chennai, 603110 and Research Scholar,
Dept of MechEngg, NIT Calicut,
2
Department of Mechanical Engineering, NIT Calicut,
3
Department of Mechanical Engineering, NITC, 673601,
1*
The present investigation focuses on the synthesis and machinability studies of A356 alloy-15 vol % SiC
particle reinforced metal matrix composite (MMC) synthesized by vacuum hot pressing technique. The
effect of cutting speeds, feed and depth of cut on the machinability of the composite in terms of cutting
forces, tool work interface temperature and material removal rate are investigated in the shoulder end
milling process with uncoated carbide insert. The experimental plan and analysis were carried out based on
the box-behnken based design. Cutting force measurements showed that the cutting force increased from 37
N to 109 N with an increase in the feed rate and depth of cut, but decreased with an increase in the cutting
speed. But the increase in machining parameters increased the tool work interface temperature from 31°C to
35°C and MRR from 1.4 mm3/min to 11 mm3/min. Optimum machining parameters were identified and
verified with confirmation experiments to improve the machinability of the material.
Keywords: A356 alloy-15% SiC metal matrix composite, Vacuum hot pressing technique, Machinability
study, Optimization
An Experimental Investigation on Designed and Fabricated WECSM Setup during
Micro Slicing of e-glass Fibre Epoxy Composite
Alakesh Manna* and AnupMalik
Department of Mechanical Engineering, PEC University of Technology, Chandigarh-160012,
Research Scholar, Department of Mechanical Engineering, PEC University of Technology, Chandigarh,
160012,
*
The e-glass fibre epoxy composite is a nonconductive ceramic material hence it is difficult to machine by
any well known non-conventional machining methods like electrical discharge machining, wire electrical
discharge machining etc. This material can be machined with conventional machining but compromise with
accuracy, surface texture even not possible to micro slicing etc. Keeping in view, a hybrid machining
technique which is combination of both electro chemical machining (ECM) and wire electric discharge
machining (WEDM) is used to machine such material. This paper presents the results during machining of
e-glass fibre epoxy composite on a designed and fabricated wire electrochemical spark machining
(WECSM) setup. The numbers of experiments have been carried out to investigate the effect of different
parameters of fabricated WECSM setup on machining performance characteristics such as material removal
and spark gap width. Test results revels that the width of micro slicing was very small e.g.127 m. The
practical research analysis and test results present in this paper will provide new guidelines to the
manufacturing engineers and upcoming researchers.
Keywords: Hybrid machining, WECSM, E-glass fibre epoxy composite, Micro slicing.
A comparison study of filament wound composite cylindrical shell used in under water
vehicle application by Finite Element Method
Abhijit Dey1, K.M.Pandey2 and P.L.Choudhury3
1
NIT Silchar, Dept. of Mechanical Engg, Assam, 788010,
2
3
The most important property required in any structural material is high strength to weight ratio and
corrosion resistance, hence composite materials gained grater interest in this field. The body of Unmanned
Underwater Vehicle (UUV) is made up of composite cylindrical vessel which is subjected to different kind
of loads when they are travelling in their respective environment. Buckling and post-buckling are the most
dominant failure mechanism when the external hydrostatic pressure reached at elevated level in case of
composite UUV. The present research was aimed to comparing the performance of stiffened and unstiffened filament wound composite pressure vessel used for under water vehicle application. The cylinder
is made by carbon/epoxy composite material; the winding pattern is [±60/90] FW for both the cases. The
analysis has done by using finite element software ANSYS 14.0 APDL. 10 MPa external hydrostatic is
applied which is equal to the pressure at a depth of 1000 m in water. The analysis results showed that the
stiffened composite shell give the higher value of critical buckling pressure.
Keywords: Composite Pressure vessel, Buckling, ANSYS, Stiffener.
A Study on Evaluation of Mechanical and Thermal Properties of Rice Husk Filled
Epoxy Composites
Arun Kumar Rout*1, Alok Satapathy2, Ashok Kumar Sahoo3 and Dipak Kumar Jesthi4
1*
School of Mechanical Engg, KIIT University, Bhubaneswar 751024 (India)
2
Department of Mechanical Engineering,National Institute of Technology, Rourkela 769008
3
4
This paper presents a study on the thermal and mechanical characterization of a new class of multi-phase
composites consisting of epoxy resin reinforced with glass fiber and filled with rice husk particulates. Four
different sets of glass-epoxy composites are fabricated with addition of 0, 2.5, 7.5 and 12.5 wt% of rice husk
particulates. Tensile, flexural, micro-hardness and inter-laminar-shear-strength of these composites are
evaluated as per ASTM standard. It is observed that micro-hardness of the composite is increasing while
tensile and flexural properties are decreasing with addition of rice husk. Further, six different sets of epoxy
composites are fabricated reinforced with 2.5, 5, 7.5, 10, 12.5 and 15 wt% of rice husk particulates for
thermal characterization. The effective thermal conductivity, coefficient of thermal expansion (CTE) and
glass transition temperatures (Tg) are studied for theses composites. It is found that the effective thermal
conductivity (Keff.) and CTE of neat epoxy are reduced by 74.38% and 22% respectively and the Tgis
increased by 140C with addition of (15 wt%) rice husk content.
Keywords: Polymer matrix composites, Rice husk, Mechanical characterization, Thermal characterization
Application of grey fuzzy logic for simultaneous optimization of surface roughness and
metal removal rate in turning Al-SiCp metal matrix composites
Santosh Tamang1 and M. Chandrasekaran*2
Department of Mechanical Engineering, NERIST, Nirjuli, Arunachal Pradesh, INDIA 791109,
Email:[email protected], *[email protected]*2
Metal matrix composites (MMCs) are difficult to machine due to the presence of hard abrasive
reinforcement materials. The selection of optimum machining parameters is essential for economic
production of quality components. The present investigation focuses on finding the optimal turning
parameters considering multiple performance characteristics using grey fuzzy logic approach. Taguchi’ s L27
orthogonal array of experiments was performed in turning Al-SiCp MMC using poly crystalline diamond
(PCD) tool. Two important performance measures i.e., surface roughness (Ra) as a parameter for job quality
and material removal rate (MRR) for economic production of the components were optimized. The grey
output is fuzzified into eight membership functions and 27 rules were developed. The highest grey fuzzy
reasoning grade (GFRG) obtained using MATLAB 7.10® tool box shows the grade improvement of 0.12 in
comparison with grey relational grade (GRG). The proposed grey fuzzy logic approach found more
effective to evaluate the multiple performance characteristics and simplifies the optimization procedure in
optimizing complicated process responses.
Keywords: Grey fuzzy logic, MMC, Machining, Optimization
Abstracts of Rapid Prototyping
Papers
Machine Element Reconstruction Using Integrated Reverse Engineering and Rapid
Prototyping Approach
Atul Kumar1,*, P.K. Jain2 and P. M. Pathak3
2
Indian Institute of Technology Roorkee, India-247667, Uttarakhand,
3
Indian Institute of Technology Roorkee, India-247667, Uttarakhand,
1,*
The modern manufacturing industries are characterized by a wide spread use of remanufactured products.
Thus there is a need of hour to fabricate an object by integrating the reverse engineering and rapid
prototyping approach to facilitate the re-manufacturing process. This integrated approach might be reducing
considerable product makeup time. Existing all integrated reverse engineering and rapid prototyping
methodology are begin with the digitizing of an entire object surfaces. Reverse engineering technology
enables to create CAD models of existing objects by capturing their surface data and rapid prototyping is
another emerging technology that allows to promptly fabricating the physical prototype of a product using
an adaptive manufacturing technique. In this research, a method that creates a direct link between reverse
engineering and rapid prototype technologies to fabricate the physical model of scanned object has been
proposed. Spur gear has been selected for the present work because of owing to its complex geometry and it
is considered to be an imperative element in mechanical industries to transmit power between two parallel
shafts. In the present work a spur gear is scanned to re-generate its CAD model. The scanned recreated
model in STL format is fabricated by rapid prototyping approach using Object30-Pro machine. Finally, the
original and fabricated models are use to compared for its critical geometrical dimensions and tolerances.
The spur gear example gives an insight of how integrated approach can cater the requirements of industries
especially the automotive sector.
Keywords:Spur Gear, Reverse Engineering, Rapid Prototype, 3D Laser Scanner, Point Cloud Data, 3D
printing
Study and Analysis of Metallized electrode fabricated with FDM Rapid Prototyping
technique for Electro Discharge Machining (EDM).
Fefar Savan D. 1 and J.S. Karajagikar2
Department of Production Engineering and Industrial Management, College of Engineering, Pune-411 005
E-Mail: [email protected].
2
Department of Production Engineering and Industrial Management, College of Engineering, Pune-411 005
Electro Discharge Machining (EDM) is a non-traditional machining process for the manufacturing of
complex or hard material parts that are difficult to machine by traditional machining processes. In DieSinking EDM, the electrode shape is mirrored on the workpiece. Hence, instead of the machining problems,
the process of electrode manufacturing becomes critical. The conventional methods of electrode
manufacturing are not competent with the emerging demands of complex structures and shorter lead time.
Rapid tooling (RT) technique by rapid prototyping (RP) process has potential to overcome the problem of
conventional methods of tool manufacturing. In the present work, Fused Deposition Modeling (FDM)
process of rapid prototyping is employed to develop the electrode for electro discharge machining. The
ABS electrode produced by FDM process was metallized by electroless copper coating to make the RP1
electrode conductive. Experimental work and analysis are carried out to investigate the feasibility of RPelectrode for EDM. The various input parameters such as discharge current, discharge Time, and discharge
Voltage are observed and further analysis of Material Removal Rate (MRR), Tool Wear Rate (TWR) and
surface roughness (Ra) are carried out.
Keywords: Electro discharge machining (EDM), Rapid Tooling (RT), Fused Deposition Modeling (FDM)
Physical Replication of Human Bone by Using Direct Integration of Reverse
Engineering and Rapid Prototyping Techniques
N. N. Kumbhar1*, A. V. Mulay2and B. B. Ahuja3
Production Engg. Dept., College of Engineering, Pune - 411005,
2
Production Engg. Dept., College of Engineering, Pune – 411005
3
Production Engg. Dept., College of Engineering, Pune – 411005
1
The replication of an existing object of complex shape is one of the typical applications of the integration
between two modern computer-based technologies, reverse engineering (RE) and rapid prototyping (RP).
The method is multipurpose and can be used in various applicative domains like mechanical components,
house hold equipments, bio-medical, anatomical parts amongst others.
This paper presents a process to construct 3D rapid prototyping (RP) physical models of human bone by
using 3D point cloud data which is obtained from 3D laser scanner. This process is achieved by generating
the triangular mesh directly from 3D point cloud data without developing any surface model using any
commercial CAD software. The generated STL file from 3D point cloud data is used as a basic input for RP
process. The Delaunay Tetrahadralization approach is used to process the 3D point cloud data to obtain STL
file. 3D point cloud data of Metacarpus (human Bone) is used as the case study for the generation of the 3D
RP model. Once this STL file is obtained, a 3D physical model of the human bone is generated on Rapid
Prototyping machine and its virtual reality model is presented for visualization in STL format. The results of
this research are assessed for clinical reliability in replication of human bone in medical field.
Key words: Reverse Engineering, Rapid Prototyping, 3D Point Cloud Data, Delaunay Tetrahedralization,
STL file, Human bone.
Integrated AHP and fuzzy TOPSIS Approach for the Selection of a Rapid Prototyping
Process under Multi-Criteria Perspective
Biranchi Narayan Panda1*, BibhutiBhusan Biswal2 and B B L V Deepak3
1,2
Department of Industrial Design, NIT Rourkela-769008
1*
[email protected]
2
[email protected]
3
[email protected]
Rapid prototyping (RP) is a promising technology that has been implemented in many spheres of industry,
particularly in the area of new product development due to its unique characteristics of fabricating
functional prototypes timely and efficiently. Recent years have seen various rapid prototyping (RP)
processes such as stereolithography(SLA), selective laser sintering (SLS), fused deposition
modelling(FDM), and laminated object manufacturing (LOM) which can fabricate three dimensional(3D)
solid models directly from the computer aided design (CAD) data without any tooling and human
intervention. However, selection of an optimal RP system for the end use of a part is a tedious work due to
involvement various criteria or objectives in the decision making process and it is often necessary to
compromise among possibly conflicting factors. Thus, the multiple criteria decision making (MCDM)
becomes a useful approach to solve this kind of problem. This study proposes an integrated Analytic
Hierarchy Process (AHP) and Technique for Order Preference by Similarity to Ideal Solution (TOPSIS)
method for the selection of rapid prototyping system that involves multiple, usually conflicting
attributes.Theproposedmethod enables decision analysts to better understand the complete evaluation
process and provide amore accurate, effective, and systematic decision support tool.
Keywords: Rapid Prototype process selection, Multi criteria decision-making, AHP, Fuzzy TOPSIS
Intelligent Performance Modelling and Optimization in Rapid Manufacturing
UshastaAich1*, Amar M. Phatak2 and S.S. Pande3
1 , 2, 3
*
Computer Aided Manufacturing Laboratory
Indian Institute of Technology, Bombay
Mumbai 400076, India
E-mail: 1 * [email protected]
2
[email protected]
3
[email protected]
Rapid manufacturing (RM) processes overcome some limitations of traditional subtractive manufacturing.
Despite focused worldwide research, RM processes have some basic limitations such as low productivity,
high cost and part production in materials which are not functional. A need, therefore, exists to carry out
research in these directions. The work reported in this paper is primarily concerned with the development of
an intelligent performance prediction model for SLS and using it to optimize the process for efficient part
production. Three performance measures have been considered viz. productivity (build time), part quality
(stair case error) and economy (material utilization). A modular system has been developed and
implemented for process performance parameter computation at different part orientations. Radial basis
function neural network (RBFN) has been used to develop the prediction model to estimate various
individual as well as weighted process responses with excellent prediction accuracy. To obtain the optimum
part orientation angles, the models were integrated with particle swarm optimization (PSO) algorithm and
tested for complex benchmark components. The RBFN-PSO based approach reported in this work was
found to be superior to the GA based approach reported earlier in both computational time and accuracy.
Keywords: Process modeling, RBFN, PSO
Location Dependency of Positioning Error in a 3-axes CNC Milling Machine
R.K. Gupta*, S.P. Srivastava, S.K.Yadav, V. Prasad and S.B. Jawale
Centre for Design and Manufacture
Bhabha Atomic Research Centre
Trombay, Mumbai-400 085
To produce complex components within a close tolerance value, the machine tools are required to be more
accurate than the specified accuracy of the components. Generally to achieve better accuracy of machine
tools, laser interferometer systems are used to measure the positioning error and thereafter error
compensation is done to improve the accuracy. In case of big size milling machines, it is observed that the
accuracy of the machine is not always uniform throughout its work table area. This paper presents a study of
error distribution across the work table surface that enables to identify the best location for machining close
tolerance components. It also indicates the error involved in the machining, corresponding to the various
locations of the machine work table.
Keywords: Tolerance, Positioning error, Milling machine
Abstracts of Metrology Papers
Comparison of servo tracking capability of the interconnected cylinders positioning
system with servo pneumatic positioning system
Saravanakumar D1* and Mohan B2
Department of Production Technology, MIT Campus, Anna University, Chennai, India-600044.
2
Department of Mechanical Engineering, CEG Campus, Anna University, Chennai, India-600025.
1*
Servo pneumatics is a mechatronic approach that enables accurate position control of pneumatic drives with
high speed. In the present study, a new method of position manipulator with two interconnected pneumatic
cylinders is presented. Nonlinear mathematical model of the system comprising of mass flow rate, pressure
dynamics, frictional forces and motion dynamics has been formulated. Using Matlab-Simulink software, the
system has been simulated. The positioning performance of the proposed system is compared with the servo
pneumatic system with single cylinder. The simulation results shows that the proposed system has better
performance indices than existing servo pneumatic system. The interconnected pneumatic cylinders system
is observed to have satisfactory regulatory and trajectory tracking performances.
Keywords: Servo Pneumatics, Positioning systems, Mechatronics, Modelling and Simulation
Recent Advances in Burr Height Minimization in Micro-Machining
Muddu Allaparthi and Mohammed Rajik Khan*
National Institute of Technology, Rourkela, India, 769008
Email:[email protected], *[email protected]
Micro machining is a commonly used industrial process to produce micro components. The miniaturization
of the cutting tools provides tremendous scope of research to enhance various micro machining process and
finished micro parts. This manuscript reviews the state of the art in micro-mechanical machining. Its focus
is on micro-milling and drilling processes as these are most flexible for creating complex 2D & 3D surfaces.
This work aims to put into perspective various modeling approaches for micro-milling and drilling
operations and to identify the strengths and weaknesses of these models. A comprehensive report on recent
progress in modeling and experimental evaluation of burr formation in micro-machining primarily, targeting
industrial applications is presented. Also, a roadmap for future directions in line of burr minimization in
micro-machining is proposed.
Keywords: Mechanical micromachining, Micro-milling, Micro-drilling, Burr minimization.
Predication of surface roughness of freeform surfaces using Artificial Neural Network
1
1
Rajesh M. and 2R Manu
SHARDA University, Greater Noida,
2
NIT Calicut, Calicut Kerala,
Sculptured surfaces can be defined as models or parts consisting of complex counters or consisting of
known networks of points, vectors and curves. Theses surfaces are usually created by blending of curves to
form surfaces. Freeform surfaces are usually produced by using a CNC Machine. Sculptured surfaces find a
wide a range of application in field of Aerospace, Automobile die and mould industries etc where
maintaining surface quality is important priority. Issues arise during measuring the surface roughness of
these freeform surfaces. Since the surface profile of these surfaces are irregular in shape and size. Therefore
to overcome this problem replication techniques is used and further experimental runs were established
which relate the speed, depth of cut, feed rate and stepover on the quality of the surface produced by CNC
ball end milling. Further Artificial Neural Network (ANN) is utilized which is a state of the art artificial
intelligent method that has possibility to enhance the prediction of surface roughness
Keywords:VMC, Freeform Surfaces, Replica Tape, Surface Roughness, Artificial Neural Network
Blind Assembly Using Digital Metrology for Satellite Applications
C. Koteshwara Rao1*, Rohit Jain1, Pravesh Mathur1 and Govinda K. V1.
*1 Systems Integration Group, ISRO Satellite Centre, Bangalore
A typical Spacecraft is a cuboid structure comprising of sensitive and fragile elements such as antennae,
sensors and actuators protruding out of the cuboid which define the overall volume of the spacecraft.
Satellites need to be transported to launch base either by road or by air (in a cargo aircraft) in a specially
designed container. The gap between the spacecraft and the inner wall of the container is to be kept as
minimum as possible in order to minimise the size of the container so that it is possible to be accommodated
inside the cargo aircraft. Safe transportation is one of the important activities which have to be performed
with utmost care. Any damage to the spacecraft elements during transportation will be catastrophic to the
mission.
As the spacecraft size grows optimizing the internal volume of the spacecraft container becomes a
challenging issue. Optimizing position and orientation of the spacecraft inside a container is very critical.
Once the container lid is closed it is a tedious task to measure the gaps between the container lid and the
spacecraft elements using conventional metrology techniques. In case any major anomaly is observed the
project schedule is also affected. In such scenarios it is advisable to make the assessment during fabrication
of the container well in advance and modify the orientation of the special fixture inside the container
accordingly. Dummy models of the spacecraft volumes are necessary for such assessments since the satellite
cannot be transported to the fabrication site. Nor can the container under fabrication be moved to the
satellite production area due to cleanliness requirements, weight, volume, time and cost for these activities.
Any change in spacecraft configuration calls for change in the dummy model and thereby increasing the
time and cost of production.
This paper describes newly developed digital metrology technique using Closed Range Photogrammetry for
blind assembly of spacecraft containerisation. Using this technique, it is possible to verify by measurement,
the gaps and interferences very accurately, to the tune of microns without bringing the 2 massive parts viz.,
the satellite and the container, at one place. The technique provides vital inputs to the designer without
asking for dummy models and also improves the accuracy of the assembly.
Key words:Digital metrology, Blind Assembly, Satellite containerisation, Photogrammetry.
Study of Profile Changes in Magneto-rheological Abrasive Honing By an Ingenious
Relocation Technique
S. Chidambara Kumaran1 and M.S. Shunmugam2
Dept. of Mech. Engg., IIT Madras, Chennai-600036, India
2
Dept. of Mech. Engg., IIT Madras, Chennai-600036, India,
Magneto-rheological abrasive finishing is a non-traditional method of improving the surface finish of
manufactured components. Performance of different variants of this finishing process in terms of surface
roughness parameters andmaterial removal with process variables have been reported in the literature. In
this paper, an ingenious relocation profilometry is employed to study the changes in the surface during the
process by tracing the same profile again and again. Analysis of the relocated profiles brings out the gradual
changes in the profile and also the metal removal during the process unambiguously. The results of analysis
are reported and discussed.
Keywords: Magneto-rheological abrasive finishing, Relocation profilometry, Surface roughness, Material
removal
1
Abstracts of Material Science
Papers
Experimental Investigations of Ni/La2O3 Composite Micro-Cladding on AISI 1040
Steel through Microwave Irradiation
Arbind Prasad1*, Dheeraj Gupta2, M. Ravi Sankar1 and A. Naryana Reddy1
1*
Department of Mechanical Engineering, IIT Guwahati, Guwahati, 781039, India
2
Department of Mechanical Engineering Thapar University, Patiyala, 147004, India
E-Mail: 1*[email protected], [email protected],[email protected],
1
[email protected]
AISI 1040 steel is widely used material in most of industrial manufacturing applications. In order to meet
the increasingly demanding stringent operating conditions, the functional surface of the concerned
components which are made of AISI 1040 are modified in such a way that they can sustain in the aggressive
environment. In this paper cladding of Ni/La2O3 composite powder (particle size ~40µm) has been done
through microwave irradiation. This processing has been explored for enhancement of surface properties of
AISI 1040 steel. The favourable property of microwave processing is that the volumetric nature of heating
of the material results in uniform thermal gradient, which yields uniform material properties in the
processed materials. The developed Ni/La2O3 composite clad surfaces on AISI 1040 steel substrate was
characterized using scanning electron microscope for surface morphology. The average thickness was
observed to be ~500 µm and the developed Ni/La2O3 composite clad surface shows good metallurgical
bonding with the AISI 1040 substrate material. The mechanical property such as hardness were also
measured and found to be improved.
Keywords: Microwave, Cladding, SEM, Vickers hardness
Some Chemo-Rheological studies of aqueous Silicon Nitride suspensions in gelcasting
process
T. Nagaveni1*, K. Kishore Kumar2 and C. S. P. Rao3
Department of Mechanical Engineering, National Institute of Technology, Warangal, India.& Department
of Mechanical Engineering, University College of Engineering, Osmania University, Hyderabad-500007,
Andhra Pradesh, India.
2
Department of Mechanical Engineering, National Institute of Technology, Warangal, A.P., India.
3
Department of Mechanical Engineering, National Institute of Technology, Warangal, A.P., India.
1*
Gelcasting is a near net shape manufacturing process being widely used in manufacturing of complex
ceramic parts. Chemo-rheological properties of ceramics suspensions are ought to be known for acquiring
desired properties of ceramic parts. In this paper, the rheological and chemo-rheological properties of
aqueous -Si3N4 suspensions for gel-casting as well as their precursor solutions of Methacrylamide (MAM)
and N,N’ -methylenebisacrylamide (MBAM) were studied using stress viscometry techniques. The milling of
Y2O3 and Al2O3 with silicon nitride is carried. The zeta potential of the as-received Silicon nitride particles,
mixed powder and mixed powder in the presence of the DOLAPIX A88 were measured. The suspension of
mixed powder was prepared at different dispersant content and ball milling time and studied the rheology of
silicon nitride suspensions. It was observed that the suspensions exhibited shear thinning behaviours with
relatively low viscosity which could satisfy the gelcasting process. The influences of monomer content and
ceramic solid loading were also evaluated by means of idle time, which are significant parameters in gelcasting process. The presence of silicon nitride powder has also a catalytic effect on gelation process.
Keywords: Chemo-Rheology, Gelcasting, Silicon nitride, Zeta potential
Characterization and Optimization of ElectrospunPolyacrylonitrile (PAN) And
Polyvinylidene Fluoride (PVDF) Nanofibers
Ankit R. Chaudhary1 and B. B. Ahuja2
Department of Production Engineering, College of Engineering, Pune-411 005,
E-Mail: [email protected].
2
Department of Production Engineering & Deputy Director, College of Engineering, Pune-411 005,
1
The recent advancements in the field of technology have led to miniaturization of the object and devices; the
whole new emphasis being on creating compact and lighter, equipments and devices, to improve not only
the portability but also to reduce the overall energy consumptions. Development of the Nanofibers and their
increased use in variety of applications is a step in this direction. They can be produced by different
methods; of all these methods electrospinning the most prevalent method is widely used industrially because
of its relatively low cost, simplicity and high rate of production. Nanofibers find applications in areas such
as healthcare, defence, energy applications, biotechnology and environmental engineering. In the present
work, an attempt is made to make nanofibers of Polyacrylonitrile (PAN) and Polyvinylidenefluoride(PVDF)
in solvent dimethyl formamide (DMF).The objective being to prepare the nanofibers of minimum diameter,
by controlling the parameters. Scanning electron microscope (SEM) is used to study the diameter and
surface morphology of the Nanofibers of PAN and PVDF and hence establish the most optimized set of
parameters which will help produce fibers with minimum diameter in a commercial manner.
Keywords: Electrospinning, Nanofibers, PAN, PVDF
Surface Modification of Aluminum by Electrical Discharge Coating with Tungsten and
Copper Mixed Powder Green Compact Electrodes
Tijo D1 and Manoj Masanta2*
1
NIT Rourkela, 769008, [email protected]
2*
NIT Rourkela, 769008,[email protected]
EDM is a prominent non-traditional machining process, which is widely used for machining hard materials
which is not possible by conventional processes. A very special aspect of this process is a surface
modification by material transfer from the tool electrode to the work-piece which is commonly known as
electro discharge coating (EDC). In this work, electrode prepared with tungsten (W) and copper (Cu)
powder by powder metallurgy (PM) route used as tool material and pure aluminum is used as work-piece.
Using reverse polarity (tool as anode and work-piece as cathode) in electro discharge machine a hard
composite layer of WC-Cu has been deposited on the Aluminum work-piece surface. The effect of
compaction pressure during tool preparation by PM method and peak current (Ip) and pulse on time (Ton)
during EDC process on Deposition Rate (DR) and Tool Wear Rate (TWR) have been studied. A Taguchi
L18 experimental design method has been used to study the effect of various process parameters on EDC
process.
Keywords: Electro Discharge Coating (EDC), Powder metallurgy (PM) electrode, Deposition Rate (DR),
Taguchi analysis.
Transverse Rupture Strength of Solid Lubricant Cutting Tool Material
A. Muthuraja1 and S.Senthilvelan2*
Indian Institute of Technology Guwahati, Guwahati 781039,
[email protected]
2*
Indian Institute of Technology Guwahati, Guwahati 781039,
[email protected]
1
Solid lubricant bearings and gears find many engineering applications due to its clean environment and
maintenance free characteristics. Solid lubricant based cutting tool has potential to replace conventional
cutting tool under dry machining. In this work, tungsten carbide based material with various weight
percentage of solid lubricant, calcium fluoride was considered. Cobalt and stearic acid were considered for
binder and process control agent respectively. Materials were milled in the planetary ball mill and milled
powders were compacted uniaxially and sintered in a tube furnace. Developed materials were evaluated for
the transverse rupture strength with the aid of developed fixture and servo hydraulic universal testing
facility. From the investigation, tungsten carbide with 5 wt.% calcium fluoride found to be superior over
other investigated materials. Failure morphology of the fractured test specimen reveals the role of solid
lubricant over transverse rupture strength.
Keywords: Transverse rupture strength, Solid lubricant, Cutting tool.
Concurrent Evaluation of Electroplating Effluent Treatment System for ‘X’- Abilities
Using Graph Theory and MADM Method
Abhishek Kumar1, Shibu Clement2 and V.P. Agrawal3
Department of Mechanical and Manufacturing Engineering, Manipal Institute of Technology, Manipal –
576104
2
Department of Mechanical Engineering, Birla Institute of Technology and Science- Pilani, K K Birla Goa
Campus, Goa – 403 726.
3
Mechanical Engineering Department, Thapar University, Post Box No. 32, Patiala – 147 004.
*Corresponding author. Tel.: +91942124979.
E-mail address: [email protected] (Abhishek Kumar).
1
Electroplating Industries are deploying various waste treatment methods, for reducing the waste discharge to
the environment as well as for reuse of waste metals and oxides. Use of different methods of waste
treatment and reducing the waste discharge, requires due consideration of various abilities – performance,
reliability, environment ability, stability, maintainability, quality, etc. called X-abilities – in varying degree
of importance depending on standards/ norms required by an organization/state/country. To facilitate the
evaluation (or design evaluation) of an effluent treatment system which simultaneously accounts for all Xabilities, a concurrent design evaluation methodology using graph theoretic and multiple attributes decision
making (MADM) approach is proposed. A case study of various chromium plating is presented to illustrate
the applicability of proposed methodology.
Keywords: Concurrent design, design for X-abilities, Graph theory, MADM, TOPSIS, Electroplating
effluent treatment system
Effect of Microstructure with Hardness on Heat Treatment of HP40Nb Microalloyed
Reformer Tube
Amitava Ghatak* and P.S.Robi
Department of Mechanical Engineering, Indian Institute of Technology Guwahati,
North Guwahati, Assam, India -781039
Premature failure of service exposed centrifugally cast HP40Nb microalloyed steel are due to either creep,
fatigue or corrosion and in few cases may be due to the combined effect of these phenomenon. Limited
amount of information is available in the open literature regarding the effect of temperature and time on
microstructure and mechanical properties of these materials. The present work was aimed at investigating
the effect of heat treatment temperature and time on the microstructure and hardness of HP40Nb
microalloyed steel. Heat treatment of the steel was carried out at temperatures in the range 1073 K - 1473 K
for 8 hours and 72 hours. Presence of Cr rich and Nb rich carbides at grain boundary regions were observed.
Image analysis of optical photomicrographs revealed the 8 vol.% and 2 vol.% of Cr carbide and Nb carbide
respectively at the grain boundaries. The grain size of the HP40Nb steel increased from 64 m in the asreceived condition to 91 m after heat treatment at 1073 K whereas the grain size increased to 96 m when
heat treated at 1473 K for 72 hours. The hardness decreased only marginally when heat treated at 1073 K for
72 hours, whereas it decreased drastically when exposed at 1473K. The hardness of the steel decreased with
increase in heat treatment time.
Keywords: HP40Nb, Heat treatment, Grain size, Hardness
Numerical Modelling Of Impact and Solidification of A Molten Alloy Droplet On A
Substrate
Rajesh Kumar Shukla1, Sateesh Kumar Yadav2, Mihir Hemant Shete3 and Arvind Kumar4*
Dept. of Mechanical Engineering, Indian Institute of Technology Kanpur, Kanpur, India, 208016
1
[email protected], [email protected], [email protected], [email protected]
Most of the studies reported for droplet impact and spreading on a substrate in a thermal spray coating
process assume that droplet solidifies as a pure substance, i.e., phase change occurs at a fixed temperature.
The alloy type behaviour of the droplet impact where it solidifies within liquidus and solidus temperature is
not well reported. The role of formation of mushy zone and species composition variation during the coating
layer formation while using a multi-constituent alloy material is not known. This work investigates the
impact, spreading and solidification characteristics of an alloy droplet impacting on a substrate. Two
dimensional axisymetricmodel has been used to simulate the transient flow and alloy solidification
dynamics during the droplet impingement process. Volume of fluid (VOF) surface tracking method coupled
with the alloy solidification model within a one-domain continuum formulation is developed to describe the
transport phenomena during the droplet impact, spreading and solidification of an alloy droplet on a flat
substrate. Using the model the characteristics of alloy solidification in coating formation are highlighted.
Keywords: Alloy droplet, Thermal spray coating, Droplet impact and spreading, Solidification.
Enhancement of Mechanical properties of recycled
Green sand by addition of Alumina
A.K. Birru1*, L. DharamSingh2 and P. Arun kumar3
1, 2,3
1, 2,3
Christu Jyothi Institute of Technology & Science, Jangaon, India
Foundries for the metal-casting industry plays a vital role to generate by- products such as used foundry
sand. Metal foundries use large amounts of the metal casting process. Foundries successfully recycle and
reuse the sand many times in a foundry but by using repeated usage of Used foundry-sand vary due to the
type of equipment used for foundry processing, the types of additives, the number of times the sand is
reused, and the type and amount of additives which may lead to depletion of the quality of the casted
product. In this study additive like Bentonite, this promotes good green strength, moderate dry and hot
compression strength. Carbon which provides a reducing atmosphere and a gas film during pouring that
protects against oxidation of the metal and reduces burn. Saw dust which controls sand expansion and to
broadens the allowable water content was properly mixed to recycled sand to obtain the standard green sand
composition. In addition to the said composition, alumina which is a refractory material which improves
green, dry compression strength and permeability of the recycled sand. The results were compared with
green sand and recycled green sand and found that addition of alumina in improving the mechanical
properties.
Keywords: Recycled green sand, green sand, alumina, compression strength.
Size effect on mechanical behaviour of SS304
Jambeswar Sahu1 and Sushil Mishra2*
Department of Mechanical Engineering, Indian Institute of Technology Bombay-400076,
21
Department of Mechanical Engineering, Indian Institute of Technology Bombay-400076,
1
Of the available micro-manufacturing technology, micro-forming draws the attention of manufacturers and
researchers due to its high precision, low energy consumption and low cost products with better mechanical
properties. However, due to the size effect, the traditional macro-forming techniques cannot be applied to
micro-forming directly. Therefore, manufacturing of micro-components is a challenging field. When the
parts are miniaturized, adhesive force and surface tension plays an important role. The microstructure, grain
orientation, grain boundary, surface integrity are significantly influence the micro-forming process. Three
FCC materials (SS304) of 30 µm, 50 µm and 90 µm thickness were selected as working material to study
the size effect. The effects of thickness, surface grain, cross section grain size on mechanical behaviour
were investigated. The grain distribution through surface and cross section were quantified. The effect of
thickness on YS and UTS at nearly same grain size was studied and it was observed that the strength
decreases with increasing thickness from 30 to 90 µm.
Keywords: Micro-forming, flow stress, size effect, Microstructure
Accumulative Roll Bonding of AA6005 and AA1060 Metal Strip: Study on
Microstructure, Mechanical Properties and Evaluation of Minimum Bonding Criteria
SuprimSardar a,1*, Atanu Mandal b,2, SurjyaKanta Pal b,3 and Shiv Brat Singh a,4
a
Department of Metallurgical & Materials Engineering, IIT Kharagpur, Pin-721302
b
Department of Mechanical Engineering, IIT Kharagpur, Pin-721302
1*
[email protected], 2 [email protected],
3
[email protected], 4 [email protected]
The accumulative roll bonding (ARB) is a plastic deformation process, in which micro-grains and
sometimes nano-grains are produced. The Severe Plastic Deformation (SPD) processes are widely proposed
methods to produce materials with ultra-fine grained (UFG) microstructure. Among various SPD
techniques, ARB process is widely used due to its ability to produce UFGs throughout the bulk material. In
the present study an ARB process is carried out for the study of efficient bonding characteristics of AA6005
and AA1060 metal strips. Results reveal significant grain refinement along with improvement in ultimate
tensile strength. It has been observed that, if the experimental temperature and corresponding pressure
achieve their respective threshold values, then the roll bonding or the solid state welding can be successfully
joined together.
Keywords: ARB, AA6005/AA1060 composite, Grain refinement, Roll bonding
Influence of Rolling and Age-Hardening on the Hardness and Impact Properties of
Microalloyed 2219 Al Alloys
Sanjib Banerjee, Gourab Jyoti Bayan, Achyut Roy, Saurav Sarkar and Debajit Gogoi
Tezpur University, Tezpur, 784028 , [email protected]
Tezpur University, Tezpur, 784028, [email protected]
Interest in 2219 Al alloys as potential structural materials for aircraft and space applications, is mainly due
to their high strength to weight ratio. These wrought alloys are generally used after deformation processing
followed by a sequence of heat treatments. Thus a clear understanding of the process parameters related to
thermo-mechanical treatments (plastic working and age-hardening heat treatments) imparted before the final
use is necessary for obtaining the desired mechanical properties. Microalloying (< 0.1 wt.%) with elements
such as Sn, In, Cd, Ag, Si, etc. is currently being explored for achieving still higher strength to weight ratio.
The materials seldom also demand reasonably good impact strength or toughness properties with high
strength and hardness. The present research is hence aimed at investigating the influence of rolling and agehardening on the combined hardness and impact properties of 2219 Al alloy with trace and varying (0, 0.06
and 0.1 wt.%) contents of Sn.
Keywords: Aluminum alloy, Microalloying, Hardness, Impact Strength
Study of Alternative Structural Materials for Machine Tools
1*
N. Mahendrakumar, 2 S. Syathabuthakeer and 3P. V. Mohanram
1*
3
Department of Mechanical Engineering, PSG College of Technology, Coimbatore-4,
2
Department of Mechanical Engineering, PSG College of Technology, Coimbatore-4,
Email; [email protected]
Department of Mechanical Engineering, PSG Institute of Technology and Applied Research, Coimbatore-62,
Precision machine tools are required to produce precise products at high machining speeds. Hence, the
machine tool structures must possess high damping and high structural stiffness along with dimensional and
geometrical stability. A great deal of research and development is in progress on non-conventional materials
for machine tools structures. Composite materials such as ferrocement, polymer concrete, epoxy granite and
cementitious composites are replacing the traditional cast iron as machine tool structure material. This study
makes an attempt to evaluate different composite materials used in machine tool structures in respect of the
major requisite attributes namely tensile and compressive strength, high stiffness and damping. It is shown
that, of the various composite materials under research, epoxy granite and fiber reinforced polymer matrix
composite are predominant materials for the modern precision machine tool structures. The compositions of
epoxy granite used in machine tool structures and the processing techniques for manufacturing of both
epoxy- granite composite and fiber reinforced polymer matrix composite are discussed.
Keywords: Machine tool structure, Eepoxy granite, Fiber reinforced polymer matrix composite, Processing
technique
Nucleation and growth of diamond by different seeding mechanisms on cemented
carbideinserts by HFCVD process
S. K. Sarangi1*, D. K. Sahu2, S. Padhi3 and A. K. Chattopadhyay4
Reader, Mech. Engineering Department, VSSUT Burla, Sambalpur-768018
2
Reader, Mech. Engineering Department, BIET Bhadrak-756114
3
Ph.D Scholar, Mech. Engineering Department, VSSUT Burla, Sambalpur-768018
4
Professor, Mech. Engineering Department, IIT Kharagpur-721302
*
Corresponding author: Tel:+91-82607-43222, Fax:+91-663-2430204
E-mail address: [email protected]
1
An attempt was made to deposit diamond by Hot Filament CVD method on tungsten carbide inserts. The
inserts were pretreated with acid solution. This was followed by seeding of the substrates with powders of
Ti, Mo, W and diamond separately. Depositions were done at 7000C and at a pressure of 20 Torr with
CH4/H2 flow ratio of 0.5/100 SCCM. Discontinuous diamond film was obtained on the as received carbide
surface which did not undergo any pretreatment and seeding. There was no improvement in coating when
the acid treated sample was seeded with either of Ti, Mo or W powders. A continuous diamond film with
well-developed morphology was deposited when the acid treated carbide surface was seeded with diamond
powder.
Keywords: Chemical Vapor Deposition; Raman spectroscopy; X-Ray Diffraction; Diamond
Nano Red Mud –Synthesis and Characterization
C.Neelima Devi1*, N.Selvaraj2 and V.Mahesh3
1*Dept.of ME, JNTUK, Vizianagaram, A.P- 535003,
2 Dept. of ME, NIT, Warangal, A.P- 506004,
3 Dept. of ME, SREC, Warangal, A.P- 506371,
The Red mud material is subjected to high energy ball milling and converted into nano structured material.
The nano structured red mud has been characterized for its structure by X-ray diffraction studies. Micro
sized red mud obtained from the NALCO, Bhubaneswar was analyzed and milling was carried out for the
total duration of 30 hours. The samples were taken out after every 6 hours of milling and characterized for
the crystallite size and lattice strain by using X-Ray Diffractometer. The crystallite size was reduced from
400nm to 42 nm during 30 hours of ball milling.
Keywords: High energy ball mill, Red mud, Nanostructure particles, crystallite size
Fabrication of Array of Gold Nanoparticles through Thermal Dewetting and FIB
Patterning
Goswami, A.1*, Aravindan, S.2 and Rao, P.V.3
Department of Mechanical Engineering, IIT Delhi, Delhi-110016
E- Mail: [email protected]
2
3
1
This paper details an approach to generate an array of rectangular clusters of gold nanoparticles (Au NPs)
on a substrate. A nano layer of gold is deposited through DC sputter coating on a cleaned glass substrate.
The coated substrate is annealed in Ar atmosphere at 470°C for 30 minutes which results in breaking of the
continuous gold film into individual nanoparticles. For the formation of rectangular clusters of gold
nanoparticles, patterns are made on the substrate using focussed ion beam (FIB) machining. The end result
is an array of rectangular clusters of Au NPs distributed uniformly over the substrate. Ordered clusters of
Au NPs finds wide range of applications in surface enhanced raman spectroscopy (SERS), plasmonics,
biological detection etc.
Keywords:DC sputter coating, Thermal Dewetting, Gold Nano particle, Array of Gold Nanoparticles
Simulation of Fluidity in Aluminum Alloys, Superalloy cmsx4, and Ductile Cast Iron
Mohan Krishna D1 and G. S. Reddy2*
National Institute of Technology, Warangal, 506004,
2*
National Institute of Technology, Warangal, 506004,
1
Fluidity of liquid metals and alloys play an important role in casting thin walled engineered products. The
present research has focused on understanding of the fluidity behavior of narrow and wide freezing range
aluminum alloys (47100 and 51300 respectively), then extended to castsuperalloy CMSX4 and ductile cast
iron (GJS-400-18) product. The effect of pouring temperature on fluidity of these alloys was studied. The
narrow freezing range alloy (47100) has exhibited higher fluidity compared to wide freezing range alloy
(51300). Pouring temperature was optimized to accomplish finer dendritic secondary arm spacing in a dual
cup shaped ductile cast iron with narrow freezing range. Spiral and complex shaped sand and mullite molds
with molten alloys having varied superheats of 25, 50 and 100 0C over the liquidus temperatures were
simulated using a finite element method based software. An outlook shows how a modelling approach will
predict fluidity index, mold filling, fluid velocity, and dendritic secondary arm spacing versus pouring
temperature for a given spiral and complex shaped casting.
Keywords: Fluidity, narrow freezing, wide freezing, finite element method
Abstracts of Design Papers
ME Workshop, IIT Guwahati
Micro Manipulation by a Compliant Piezoelectric Micro Gripper towards Robotic
Micro Assembly
R. K. Jain1,*, S. Majumder2, Bhaskar Ghosh3 and Surajit Saha4
1
CSIR-CMERI, Durgapur-713209, Email:[email protected]
2
3
4
This paper presents a new design of mobile micro manipulation system for robotic micro assembly where a
compliant piezoelectric actuator based micro gripper is designed for handling the miniature parts. The
compensation of misalignment during robotic peg-in-hole assembly is achieved by this compliant micro
gripper because the piezoelectric actuator has capability of producing the displacement in micron range and
generates high force instantaneously. The throughput/speed analysis of mobile micro manipulation system is
carried out for picking and placing the peg from one hole to next hole position. An analysis of piezoelectric
actuator based micro gripper has also been discussed where voltage is controlled through a proportionalderivative (PD) controller. By developing a prototype, it is demonstrated that compliant piezoelectric actuator
based micro gripper is capable of handling the peg-in-hole assembly task in a mobile micro manipulation
system.
Keywords: Piezoelectric actuator, Micro gripper, Robotic micro assembly and handling
Hybrid Neural Network Based Prediction of Inverse Kinematics of Robot Manipulator
Panchanand Jha1* and B. B. Biswal2
1*,2
Department of Industrial Design, NIT Rourkela, and PIN: 769008,
E-mail: [email protected]; [email protected];
The fundamental of the inverse kinematics of robot manipulator is to determine the joint variables for a given
Cartesian position and orientation of an end effector. Conventional methods to solve inverse kinematics such
as geometric, iterative and algebraic are complex for redundant manipulators. There is no unique solution for
the inverse kinematics thus necessitating application of appropriate predictive models from the soft computing
domain. Although artificial neural network (ANN) can be gainfully used to yield the desired results, but the
gradient descent learning algorithm does not have ability to search for global optimum and it gives a slow
convergence rate. This paper proposes structuring ANN with hybridization of Particle Swarm Optimization to
solve the inverse kinematics of 6R robot manipulator. An investigation has been made on accuracies of
adopted algorithm. The ANN model used is multi-layered perceptron neural network (MLPNN) with backpropagation (BP) algorithm which is compared with hybrid multi layered perceptron particle swarm
optimization (MLPPSO). An attempt has been made to find the best ANN configuration for the problem. It has
been observed that MLPPSO gives a faster convergence rate and improves the problem of trapping in local
minima. It is found that MLPPSO gives better result and minimum error as compared to MLPBP.
Keywords: Inverse kinematics, D-H algorithm, PSO, MLP
Vibration Analysis of a Cutting Tool with Piezoelectric Bimorph
A. Garg and S. K. Dwivedy
Department of Mechanical Engineering, IIT Guwahati, Guwahati, Assam, 781039
E-Mail: [email protected], [email protected]
In this work the health monitoring of the tool is carried out by using bimorph piezoelectric patches on the
single point cutting tool in turning process. The patches are mounted on the upper and lower surface of the
shank of the tool. The vibration analysis of this system is carried out by modeling the tool as an EulerBernoulli cantilever beam subjected to transversal base excitation and periodic axial load. The loading is due
to forces exerted by work piece on the tool. Extended Hamilton’ s principle is used to obtain the governing
equation of motion which has been discretized by using generalized Galerkin’ s method to obtain the nonlinear
temporal equation of motion. Method of multiple scales is used to investigate nonlinear response, generated
voltage due to piezoelectric patches of the system. Two resonance conditions have been studied and it is shown
that while the simple resonance condition produces the voltage in the order of micro volt, the principal
parametric resonance condition yields a voltage in the order of milli volt. By proper calibration one can use
this proposed method for condition.
Keywords: Bimorph, Periodic axial load, Method of multiple scales
Thermal Stress and Creep Analysis of Failed Tube of Secondary Super Heater
Parit A. N.1*, Tadamalle A. P.2and Ramaswamy V3
Department of Mechanical Engineering, Sinhgad college of Engineering, Vadgaon (Bk), Pune,
India 411 041,
*,
)[email protected]
2
Department of Mechanical Engineering, Sinhgad college of Engineering, Vadgaon (Bk), Pune,
India 411 041,
3
Aprameya Associates, Baner, Pune. India 411 041,
1*
Super heater is an inevitable component of any boiler system. Failure of super heater leads to breakdown of
whole plant. This paper is aimed at thermal stress and creep damage analysis of secondary super heater tubes.
Computational fluid dynamic analysis of secondary super heater block is carried out which shows disturbed
flue gas flow pattern and overheating in some regions of super heater. Fairly high temperature values on
bottom bends of tube panels are seen in conjugate heat transfer analysis. Affected tube panels are analyzed for
thermo-structural stresses using Ansys under combined as well as isolated pressure and temperature effect. The
stresses are found within safe limits under isolated pressure and temperature loads however under combined
loading larger values of thermal stresses are seen on affected bottom bends of the super heater panel. The flow
modifications were carried out to get better heat transfer and uniform temperature on the super heater. Post
flow modification stress analysis shows lower stresses in on bottom bends due to uniform flow and improved
temperature profile on super heater. The failure regions of the super heater tubes are found out by high
temperature areas and stress obtained from thermo structural analysis. These results are verified respectively
with creep analysis of the failed tube and ground data.
Keywords: Super Heater, Computational Fluid Dynamics, Thermal stresses.
Hybrid Edge Detection Technique for Part Identification in Robotic Assembly System
under Vision Guidance
Bunil Kumar Balabantaray1*and Bibhuti Bhusan Biswal2
1,2
Department of Industrial Design, NIT Rourkela-769008
*1
2
Vision system plays an important role in making an autonomous robotic assembly system. Detection of part
and identification of the correct part are important tasks which need to be carefully done by a vision
system to initiate the process. This process consists of many sub-processes wherein the image capturing,
digitizing, analysing and enhancing, etc. do account for reconstructive the part for subsequent operations. Edge
detection of the captured image plays an important role in the entire image processing activity. In this paper a
hybrid approach for detecting edges is proposed for the identification of the part in robot assembly system. The
concept of fuzzy partition is used along with wavelet transformationoperator. Based on the entropy calculation
it is found that the proposed technique is producing better result than the other edge detection techniques like
Canny’ s, Perwitt, Sobel, and Laplacian of Gaussian. This work is performed on the Matlab R2012a.
Keywords: Edge detection, Thresholding, Fuzzy probability, Fuzzy partitioning, Entropy, Wavelet
transformation
Constraint and Inverse Kinematic Analysis of 3-PRS Parallel Manipulator
Yashavant Patel1* and P. M. George2
Department of Mechanical Engineering, A D Patel Institute Of Technology-388121
New Vallabh Vidyanagar, Gujarat, India
2
Department of Mechanical Engineering, Birla Vishvakarma Mahavidyalaya-388120
Vallabh Vidyanagar, Gujarat, India
1*
Parallel manipulators are one family of devices based on closed loop architecture, which is an emerging field
in robotics. Closed kinematic structures of parallel manipulators have inherent characteristics of higher
structural stiffness, less accumulation of joint errors and enhanced pay load capacity. Many potential
capabilities of such manipulators over serial one have gained their usage in various fields of applications like
precise manufacturing, medical surgery, space technology and many more. The present work addresses
analytical generic form of inverse kinematic solution of 3-PRS configuration. In this paper, axially symmetric
3-PRS parallel manipulator configuration with 3-DOF is considered for precise manufacturing applications.
There are three identical limbs with only one active joint in each limb support a moving platform and make it
three degrees of freedom
fully parallel configuration. Mobility analysis is carried out. The equations
for position and orientation constraints are also derived for the configuration. The inverse kinematic problem
is solved using n-independent variable for n- degrees of freedom mechanism. The obtained results are
validated for assumed structural parameters with direct kinematics solutions. It is observed that there is a
unique solution for a specified pose of an end-effector within workspace due to fully parallel nature of 3-PRS
configuration.
Keywords: Parallel manipulator, Inverse kinematics, Constraint equations
FabricationAnd Pose Control of 2T2R-Based Parallel Manipulator For Drilling
Operation
Binyam P.K.1* and Sudheer A.P.2
NIT Calicut, 673601, *,
)[email protected]
2
NIT Calicut, 673601, *,
)[email protected]
1*
In recent years, progress in the development of parallel manipulators has been accelerated since they possess
many advantages over serial manipulators in terms of high accuracy, stiffness, high load to weight ratio etc.
The number of limbs is a crucial parameter in parallel mechanisms. As the number of limbs increases the
degrees of freedom (dof) increases. However it adversely affects the workspace and limb interference.
Therefore the hybrid systems which contain three links became the interesting area of research especially for
machining operations. Such kind of parallel kinematics machines (PKMs) will provide three dof using three
parallel limbs and additional two dof by serial mechanisms. This work proposes a new configuration for a
parallel kinematic machine which contains only three links but can control four parameters, two positions and
two orientations. This mechanism has a provision for adding an extra dof separately for providing five-axis
machining capability.
Keywords: Parallel kinematic machine, Parallel manipulator, Workspace
Fabrication and Control of Vision Based Wall Mounted Robotic Arm for Pose
Identification And Manipulation
Induraj R1*and Sudheer A P2
1*
NIT Calicut, 673601,
E-mail: [email protected]:
2
NIT Calicut, 673601
Locating and handling different work part configuration in a material handling system is more effective with
the assistance of a vision system. Usually object identification done through RGB image which is illumination
sensitive and other interferences from the surrounding. These limitations can be avoided if object recognition
is done by depth segmentation. This work is a 3D vision sensor based work piece re-orientation. The work
piece is changed to the desired orientation by a wall mounted robotic arm. In industries delta robots are used
for fast response but it is not capable to handle all work part configurations. This is solved using a serial
manipulator which is having four degrees of freedom. This work also presents modeling, kinematic and
dynamic analysis of the robotic arm. This project work focus on real-time object pose recognition based on
point cloud approach. It can be applied for the automation of any work cell with the vision assistance. Main
focus of the work is on control of the manipulator by processing the point cloud data.
Keywords: Work piece handling, Vision Assisted Robot, 3D Vision, Re-orientation
Design of Multimode Microwave Cavity for Materials Processing
Dharmendra Singh Rajpurohit1* and Rahul Chhibber2
Centre for Energy, Indian Institute of Technology Jodhpur, 342011,
2
Centre for Energy, Indian Institute of Technology Jodhpur, 342011,
1*
This paper presents design and simulation of a multimode microwave cavity at 2.45 GHz for materials
processing. Microwave cavity with dimensions 305mm x 203mm x 305mmhas been modelled with two
waveguide ports to couple two generators using CST Microwave Studio 2012® commercial software. Adding
one more microwave input to a multimode cavity can result in increased heating power and field uniformity if
designed properly. The Design goal of microwave cavity is to couple two low power microwave generators to
generate more heat power. The waveguide port arrangement is done so as to obtain uniform field distribution
and low coupling between two generators. Different locations of waveguide ports were simulated and cavity
was optimized to obtain low coupling and uniform field distribution.Simulation results show that a minimum 38.3db mutual coupling was achieved with two waveguide ports arranged perpendicularly in cross current
polarization. Simulated results show that Electric field distribution inside the microwave cavity with this
waveguide port arrangement is well uniform.
Keywords: Applicator, Multimode, Cavity, Waveguide.
Studies on Green Design & Manufacture of Hybrid Vehicle
Dutta, P.P. *1, Das, D.1, Dutta, M*1, Shukla, A.K. 1, Gogoi, T.K.1 and Das, A.1
1* Department of Mechanical Engineering Department, Tezpur University, 784028
E_mail:[email protected], E_mail:[email protected]
Solar photovoltaic and bio fuel are emerging and promising renewable energy sources for future automotive
propulsion in hybrid power mode. Therefore, hybridization of vehicles i.e., coupling of battery-powered
motors together with internal combustion engine is a green technology. Hybrid vehicles with internal
combustion engine powered by biodiesel-blended fuel and batteries charged by electric power and
regenerative-braking have been considered for present study. A lightweight vehicle with low rolling resistance
and aerodynamic drag is supposed to have better fuel economy. Some special techniques of weight reduction
and the use of some lightweight material have been proposed. To minimize cost, energy and raw material
consumption, recycling of used materials may be done wherever possible. Emphasis on appropriate
microstructure of steel has been put to meet strength, toughness, etc., requirements for various parts of the
vehicle. Biodiesel is one of the most promising green fuels for future automotive propulsion. Studies show that
B20 blend yields low hydrocarbon emissions. Therefore, this vehicle is a parallel type hybrid in which engine
powers the front wheels of vehicle and solar energy is used to recharge the battery that propels the electric
motors coupled to the rear wheels. Splitting of power between engine and electric motor may be achieved by
inducing the driver to modulate the pedal position until the desired vehicle power is reached. Li-ion batteries
have been reported capable of many thousands of deep discharge cycles. Li ion batteries with specific power of
2000 W kg−1 and a specific energy as high as 400 W kg−1 may be used. The auto ignition temperature of biodiesel is more than diesel. It is reported that the viscosity of biodiesel increases as the fuel temperature
increases. This may be accomplished by preheating the biodiesel through a compact heat exchanger with
exhaust gas. As a result, biodiesel viscosity decreases that atomizes it effectively. This would minimize the
emission of gases like carbon monoxide due to incomplete combustion of fuel. By utilizing waste exhaust heat,
we increase combustion efficiency of the vehicle and make it more eco-friendly from renewable energy
sources.
Keywords: Green power, Manufacturing, Electric, Hybrid
Development of an Efficient Hybrid Tricycle
P. P. Dutta1*, S. Sharma2, A Mahanta1, S Gupta1, A. Choudhury1, K. Barman1, D. Barua1, R. Gogoi1
and A. Das1
1*
Department of Mechanical Engineering, School of Engineering, Tezpur (Central) University, Tezpur, Assam,
India,
2
Department of Electronics and C. Engineering, School of Engineering, Tezpur (Central) University, Assam,
India,
E_mail: [email protected]
Tricycle rickshaw is a very cheap means of short distance transportation both in city and in rural areas.
Tricycle rickshaw is generally propelled by human energy. A study has been performed with the existing
model and design of tricycle rickshaws. It has been observed that traditional rickshaws use age-old technology,
poor mechanical design and hence non-ergonomic in maneuverability. An effort has been directed to design a
lightweight, high strength, and ergonomic both human pulled and electric powered hybrid rickshaws. The
proposed model is powered with 400 W, 24 V DC permanent magnet motor, in addition to human power. Both
the options may work independently as well as in parallel hybrid mode. The structural design of the rickshaw
has been analyzed using Autodesk inventor software to see the effect of different unbalanced stresses. It was
observed that overall structural design was safe. The rear part of the tricycle was less effected (0.0001249 Pa)
whereas front link connects to front wheel is more likely to affect (1.4438e8) by different unbalanced impacts
tests.
Keywords: Hybrid, Tricycle, Efficient, Electric
Design and Development of Automated Vegetable Cutting Machine
Tony Thomas A.1*, Muthu Krishnan A.2 and Sre Nandha Guhan K.S.3
2
1*
3
Automation was the rage of the engineering world. The investigation on the existing vegetable cutting machine
reviews the following drawbacks such as high investment cost, the contamination, additional manpower and
time consumption caused by manual processing. The setup involves a hopper arrangement and the pressure
block is actuated by a pneumatic cylinder, and has a reciprocatory motion along the vertical length of casing,
while the cutting grid remains fixed. The air supply to the cylinder is controlled by a solenoid actuated DCV,
which is controlled by a microcontroller. The entry of vegetable into the grid apparatus is controlled using a
pneumatic cylinder along with a single bar mechanism. The vegetables are feeded via inclined tube. A tray is
placed at the bottom of the apparatus to collect the vegetable pieces after processing. Variable pressure setting
for cutting different vegetables is carried out by the microcontroller. The intricacy involved with such a system
is the type of vegetables it can process. The system is advantageous in the fact that existing automation is high
in cost, and the power consumption is high. The proposed work is benefitted by pneumatic power, which is
abundant.
Keywords: Automation, Relays, Microcontroller, DCV
Inverse Kinematic Modelling of a 6-DOF (6-CRS) Parallel SpatialManipulator
Yogesh Singh1 and Santhakumar Mohan2*
Center for Robotics and Control, Indian Institute of Technology Indore, MadhyaPradesh - 453441,
2*
Faculty of Mechanical Engineering , Indian Institute of Technology Indore, MadhyaPradesh-453441,
1
Spatial parallel manipulators have a lot of applications because of their robustness and the accurateness in the
performance of the system which is associated with parallel kinematic machines. This paper presents a novel
six degrees-of-freedom spatial platform with a 6-PRRS (Prismatic-Revolute-Revolute-Spherical) or 6-CRS
(Cylindrical-Revolute-Spherical) configuration with six active prismatic joints and six rotary joints – all
attached with the base platform - thus giving it six degrees of freedom. The closed-form inverse kinematic
solution for the platform is established in this paper. Each leg have the combination of these joints : one
prismatic joint , two rotary joint with different rotational axes and one spherical joint. Prismatic joint attached
with the base platform/fixed platform as a vertical leg to ensuring better rigidity and control prospects. Its first
rotary joint with prismatic joint will act as a cylindrical joint. All six legs end in a spherical joint which are
linked together by the end effector (movable platform). The inverse kinematic solution is validated through
numerical simulation using MATLAB and ADAMS multibody software and the results are presented here
which is showing the accuracy of the closed-form solution.
Keywords: CRS, Spatial parallel manipulators , Cylindrical Joint, Multibody software.
Design and Analysis of a Single–Notch Parallelogram Flexure Mechanism Based X-Y
Nanopositioning Stage
Vithun S N*, Narendra Reddy T1, Prakash Vinod2 and P V Shashikumar3
Central Manufacturing Technology Institute, Bangalore – 560022,
*E-mail: [email protected],
1
Email: narendrareddy [email protected],
2
3
The main requirement of a mechanism for nanopositioning stage used in varieties of nanotechnology
equipments is to have minimum cross axis motion, high bandwidth and large range. This paper presents the
design and analysis of 2-DOF flexure mechanism for a nanopositioning stage. Improved compliance
mechanism is used to have minimum parasitic motion and higher bandwidth, unlike the lumped-compliance
mechanism circular hinge is used only on the drive end of the mechanism. The behaviour of mechanism is
analysed theoretically for its range and stiffness and further the designed flexure mechanism having range of
650 µm range, with high resonant frequency and negligible cross axis motion is validated with a detailed study
of dynamic and static behaviour of mechanism using FEA. Both the theoretical and FEA results confirm the
mechanism meeting the requirement for nanopositioning stage.
Keywords: Flexure mechanism, parallel kinematic, nanopositioning stage, finite element analysis.
More Special Cases in Specifying the Deviation of 3D Reference Axes
T S R Murthy1* and T Shravan Kumar2
Kothiwal Institute of Technology & Professional Studies, Moradabad-244001,
2
Daimler Commercial VehiclesPvtltd. Chennai-600096,
1*
In many precision machines and equipments, there are two or three reference axes intersecting at a point
theoretically as per the drawing. One example is gyro spin axes construction. The other examples are N/C
machine tool spindle axis and table axis as reference axes. Yet another example is the three bevel gear
reference axes of space equipment like helicopter, intersecting at a common point. In all the above examples,
theoretically the axes have to meet at a common point. But at manufacturing stage one has to specify the
acceptable deviation. Presently each axis is measured separately for its straightness or perpendicularity with
some surface. Though the axes are measured separately one cannot say to what extent they are meeting or how
closely they are approaching to the theoretical intersection point. Further there are no standards to specify this
error. The authors have earlier established and published different ways of fitting axis. Some six methods of
specifying the deviation/error were also defined. Out of these six specifications, Tangential Spherical deviation
(TSD) has more significance. This results in special cases when the viewing direction for specifying the error
coincides with one of the three axes. A simplified method for evaluating such cases is discussed in this paper.
Keywords: GD & T, Evaluation of reference axes, Error evaluation
Investigation and Analysis of Chatter Vibration in Centerless Bar Turning Machine
M. Girish Kumar*, Prakash Vinod1 and P V Shashikumar2
Central Manufacturing Technology Institute, Bangalore – 560022,
*E-mail: [email protected],
1
2
Chatter vibrations are present in almost all cutting operations and they are the major obstacles in achieving
desired surface finish. Chatter vibrations are the self excited vibrations, which has an adverse effect on surface
roughness, dimensional accuracy of the machined components. This paper investigates the occurrence of
regenerative chatter vibrations in centerless bar turning operation. The root cause for the chatter marks on
component was analysed as beat vibrations. The beat vibrations are minimized in centerless bar turning
operation to overcome the chatter marks on the machined components.
Keywords: Centerless turning, Chatter vibrations, Beat vibration
Multiple Objective Based Machine-Part Cell Design Considering Ordinal and Ratio Data
through Nsga Ii
Iti Dixit1, Saurabh Jain2 and Kapil Kumar Goyal3*
1
M M University, Mullana(Ambala), 133207,
2
College of Engineering Roorkee, Roorkee, 247667,
3*
M M University, Mullana(Ambala), 133207,
Cellular Manufacturing (CM) is an approach to harness the benefits of high production rate of a flow shop
while maintaining flexibility, and utilizing facilities, of a job-shop. CM necessitates that parts and machines
are allocated into cells to produce the identified part families so that productivity and flexibility of the system
can be improved. In this paper, an attempt has been made to propose a clustering methodology based on Nondominated Sorting Genetic Algorithm II (NSGA II) in which multiple objectives i.e. inter cellular movements
and within cell load variations are considered to generate the pareto front. The processing data like operation
sequence, machine capacity, processing time and batch sizes have been considered to form the realistic
generalized cells. The results support the better performance of the proposed algorithm. The novelty of this
study lies in the simple and efficient methodology to produce quick solutions with least computational efforts.
Keywords: Cellular manufacturing, Optimization, NSGA-II, Ratio level and Ordinal level data
Design and Analysis of Vertical Dynamic balancing machine flexure for satellite
balancing
Rajeev Chaturvedi1*, Shree Niwas Sahu2*, A Sekar3* and K.V .Govinda3*
* Systems Integration Group, ISRO Satellite Centre, Bangalore
The success of a satellite mission is dependent on the accuracy of the measurement of its mass properties.
Mass properties of a satellite viz. static and dynamic unbalance play a vital role in during satellite launching
and attitude and orbital control. Satellite’ s center of gravity (staic unbalance) and product of inertia (dynamic
unbalance) are measured in Vertical Dynamic Balancing Machine (VDBM). VDBM has key components
comprising of viz. Hydrostatic bearing, DC drive, Flexures, Velocity pick-up transducers and Data acquisition
System. The Flexures plays very important role in VDBM in determining the accuracy of machine apart from
transducers. In this paper design and analytical approach adopted for flexure design to sense the Static and
Dynamic unbalance is presented. Analytical formulation is derived for the modeling of the behavior of
flexures incorporating velocity transducer output. Experimental results are correlated with the analytical results
and are found to be in close match.
Keywords: Flexure, Velocity pickup transducer, Data acquisition system, Satellite, Centre of gravity, Product
of inertia, Finite element method
Abstracts of Tribology Papers
Evaluation of Wear Behavior of a Nonmetallic Spur Gear
Jagannath Sardar and Dibakar Bandopadhya*
Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Guwahati-781039, Assam,
India,
*Email: [email protected],
A thermoplastic composite material designed and developed for fabrication of nonmetallic composite spur
gear. The composite is fabricated using Portland pozzolanic cement (PPC) as filler material into the
polypropylene matrix followed by Injection molding technique. However, geometrical structure of the
developed product depends on the parameter like loading-unloading condition and temperature fluctuation that
severely influence the material performance and shorten the product life. In the present work, the composite
spur gear material tested to evaluate its friction and wear characteristics in adhesive and abrasive wear modes.
Weight loss due to wear of the composite gear is evaluated through direct measurement under a specific load
and running condition. It is observed that the adhesive wear rate significantly reduced when the cement filler
loading increases. This is because shear strength and surface energy of the composite material changes while
toughness and hardness of the material improves due to strengthening by cement fillers.
Keywords: Composite, spur gear, coefficient of friction, wear
Investigation of Tribological Characteristics of Non Edible Castor and Mahua Oils as Bio
Lubricant for Maintenance Applications
Amit Kumar Jain1*, Amit Suhane2
Department of Mechanical Engineering, M.A.N.I.T Bhopal MP India, 462051,
*E-Mail:[email protected]
2
Department of Mechanical Engineering, M.A.N.I.T Bhopal MP India, 462051,
1*
Lubricants have a very important role to play in every type of industry in reducing friction and wear between
two relatively moving parts. Mainly lubricants are formulated from petroleum oil which is on the verge of
extinction thus its price is also increasing at a higher rate. Furthermore these petrobased lubricants are poorly
biodegradable and toxic in nature which is highly undesirable due to environmental concerns and health and
safety of operator.
This paper represents the investigation of tribological characteristics of non edible vegetable oils as bio
lubricants. Formulated oil samples were refined castor oil and its blend with mahua oil at 10%, 20% and 30%
mixing ratio. Wear and friction analysis is done using a pin on disk wear testing machine at various parameters
like applied normal load, rotational speed and time. The results (wear rate, frictional force and coefficient of
friction) indicate that blend of castor oil with mahua oil at 20% mixing ratio have tremendous capacity for
being used in maintenance application particularly in gear applications.
Keywords: Bio lubricants, Castor Oil, Mahua Oil, Tribological characteristics.
On Improvement of Tribological Performance of Pulsed DC Cfubm Sputtered Ws2 Solid
Lubricant Coating through Addition of Ti or TiN
Tushar Banerjee1*, A K Chattopadhyay2
Indian Institute of Technology Kharagpur, Kharagpur 721302,
[email protected]
2
Indian Institute of Technology Kharagpur, Kharagpur 721302,
[email protected]
1*
The present work reports on the structural, mechanical and tribological properties of WS2 based solid lubricant
coatings. The films were deposited by pulsed DC closed field unbalanced magnetron (CFUBM) sputtering.
The deposited films were characterized by Field Emission Scanning Electron Microscopy, Grazing Incidence
X-Ray Diffraction, Scratch Adhesion test, Nanoindentation test and Pin-on-disc tribological test. Pure WS2
coating showed poor tribological performance because of its high susceptibility to atmospheric moisture and
oxidation and poor adhesion to the substrate. Addition of Ti to the WS2 film in the order of 12 % densified the
coating microstructure, improved the film hardness as well as adhesion of the film to the substrate which was
reflected in its improved tribological performance. TiN is a well known hard, wear resistant coating which has
been used for decades for combating wear on cutting tools and different sliding surfaces. However, the friction
coefficient of TiN against counter-bodies like steel is on the higher side which does not qualify TiN as an ideal
solid lubricant. Addition of tailored amount of soft, lubricious WS2 phase to the hard, wear resistant matrix of
TiN resulted in a composite coating which not only outperformed WS2, WS2-Ti but also TiN in terms of
durability and wear resistance in tribological tests because of combination of properties like hardness and
lubricity in a single matrix.
Keywords: WS2-Ti, TiN-WS2, Wear, Coatings
Abstracts on Industrial
Engineering & Operations
Research Papers
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Design and Development of Automated Test System for Aircraft Hydraulic Control
Module at Assembly and Manufacturing Floor
Karthik S. P.1, Vijay Desai2 and Kantilal L. Hirani3*
1
National Institute of Technology, Karnataka, 575025, E-Mail: [email protected]
2
3
In Aerospace Industry, Automated Test System (ATS) at the assembly and manufacturing floor improves
characterization accuracy and plays a crucial role to prove the airworthiness of the aircraft components. It is
very helpful in achieving high quality standards of aircraft components by virtue of meeting predefined
acceptance test criteria. This paper outlines a comprehensive design and development of ATS for Aircraft
Hydraulic Control Module (HCM) at assembly and manufacturing floor. It uses LabVIEW Real-Time (RT)
and PXI hardware platform to automate the Acceptance Test Procedure (ATP) for the Hydraulic Control
Module (HCM) of aircraft actuator surface. HCM plays an important role in distributing the hydraulic power to
the primary flight actuation system in an aircraft. Hence, before integrating with the actual primary flight
actuation systems, it would be subjected to ATP, as part of assembly and manufacturing level testing. The
experimental test results show that the automated Acceptance Test Procedure is effective and the parameters
under test are in good co-relation to standard values. Using good programing practices and rugged automated
test software architecture, an efficient ATS has been deployed at Assembly and Manufacturing floor. This
method is aimed at replacing the tedious and time consuming traditional method of testing the Acceptance Test
Procedure (ATP) at Assembly and Manufacturing Floor.
Keywords: Automated Test System, Actuator, Hydraulic Control Module, Data Acquisition.
Material Handling Equipment Selection using Fuzzy Axiomatic Design Principles
Anant V. Khandekar1*, Shankar Chakraborty2
Department of Mechanical Engineering, Government Polytechnic, Bandra (East) Mumbai - 400 051,
Maharashtra, India.
2
Kolkata - 700 032, West Bengal, India.
1*
Effective movement of raw material, semi-finished and finished products plays an important role in successful
operation of any manufacturing organization. Material movement from one workstation to another accounts for
about 30 to 40% of the cost of final product. Proper methods adopted for material movement are also important
for the overall safety of the personnel involved in the manufacturing processes. So, selection of the appropriate
material handling equipment (MHE) is a vital task for improving the productivity of an organization. In
today’ s technological era, numerous varieties of MHEs are readily available to carry out a desired task. At the
same time, depending on the type of material to be moved, there are many conflicting factors influencing the
MHE selection decision. For MHE selection, these factors are generally stated in both quantitative and
qualitative terms. Hence, the problem of selecting the right type of MHE for a given task can be solved using a
multi-criteria decision-making (MCDM) approach capable of dealing with a combination of crisp and fuzzy
data. In this paper, an MCDM method based on fuzzy axiomatic design principles is applied for selecting the
most appropriate MHE. Trapezoidal fuzzy numbers are employed for representing the qualitative attributes and
subsequently converting them into crisp values. As a measure of suitability, total information content is
calculated for each MHE alternative. The MHE alternative with the least total information content is regarded
as the best choice. Two real time MHE selection problems from the literature are solved to establish the
applicability and potentiality of the adopted approach.
Keywords: Axiomatic design principles, Material handling equipment, Fuzzy set theory
Application of Process Capability Indices to Measure Performance of A Multistage
Manufacturing Process
Mondal1*, S. C., Kundu2 S.
Howrah 711103, INDIA,
2
Department of Mechanical Engineering, Birbhum Institute of Engineering & Technology, P.O: Suri, District
Birbhum 731101, INDIA.
1*
A process is a unique combination of manpower, machines, methods and materials in providing a product or
service. Process capability indices have been used in the manufacturing industry to provide quantitative
measures of process potential and performance. High quality production provides advantages such as cost
saving, reduced scrap or remanufacturing, higher yield and increased customer satisfaction and market share.
Process capability indices (PCI) are extensively used in industry to evaluate the conformation of products
(process yield) to their specifications. Conventional univariate process capability indices such as Cp and Cpk
are applied to measure performance for single quality characteristic. In modern manufacturing when product
designs are complicated and consumer’ s requirements are changeable day to day, multiple quality
characteristics must be simultaneously evaluated to improve product’ s quality and also to consider correlations
exist among the quality characteristics. In this paper process capability indices (both univariate and
multivariate) are applied to measure performance in a multistage ‘locomotive wheel’ manufacturing process.
The wheel manufacturing process has three stages namely press forging, rolling and heat treatment. Process
capability indices are analysed for the above mentioned multistage manufacturing processes and the results are
compared to identify the most accurate multivariate process capability index to evaluate multiple quality
characteristics for the wheel manufacturing. The results show multivariate process capability indices (MVPCI)
proposed by Taam et al. (1993) [MCpm = 0.7923] gives higher capability compare to Chan et al. (1991) [Cpm =
0.2342] and Shahriari et al. (1995) [CpM = 0.56].
Keywords: Process capability, Multivariate process capability indices, Multistage wheel manufacturing.
Design and Development of Feature Extraction and Recognition Information System for
Computer Aided Process Planning Systems
1, 2&4
Sreenivasulu Reddy.A1*, Poornachandra Sekhar.Y2, Rajendra Prasad.T3, Ravindranath.K4
Department of Mechanical Engineering, Sri Venkateswara University College of Engineering, Tirupati –
517502 E-Mail: 1*[email protected]
3
Eqic Dies & Moulds Engineers Pvt. Ltd., Jeedimetla, Hyderabad – 500055.
The integration of automated manufacturing resources in the shop floor is one of the latest emerging research
areas.Due to lack of required data communication interface among CAD/CAM and CAPP systems it is too
difficult to generate the required process plans. At this stage the feature extraction and recognition plays a vital
role in manufacturing systemsfrom developed drawings. This feature recognition is obtained by using the
Boundary Representation (B-rep) details extracted from the STEP file (STandard for the Exchange of Product
model data)to recognize the design features. In this paper a JAVA program is developed for feature
recognition. The input data for this software is in STEP file format. The program is used to develop the
geometric data extraction algorithm, which has been developed for extracting the geometric information from
the STEP file. The program recognizes various strings in the STEP file and interprets them in terms of
machining features and recognizes the features for a part based on geometric reasoning approach by creating
link with B-rep database. A case study is presented for validation of the proposed feature recognizer.
Keywords: STEP, B-rep, Geometric Data Extraction, Feature Recognition, CAPP.
SMED (Single-Minute Exchange of Die) methodology in Garment manufacturing
Industry: Case study in reducing Style Change over Time
Jonalee D. Bajpai
National Institute of Fashion Technology, Bangalore 560102
Globalization is a major trend in developing countries. Outsourcing of services from developing countries has
become the major trend to mainly reap the benefit of cheap labor cost and raw material to a certain extent. As
a result, Textile and Garment industry in developing countries like India, China, Philippines and Bangladesh,
Sri Lanka etc. have witnessed a major demand from textile giants in USA, UK and other European countries.
Shortening of fashion cycle, shortening of lead time, competitive pricing, high quality product, socially and
environmentally compliant work place are the emerging trends of Globalization.
On one hand new management philosophies demand that product lead times are kept as small as possible. On
the other hand, product customization has increased, thereby increasing the number of parts in a product
family. As a result batch sizes have reduced and continue to shrink [4]. Garment manufacturing units in India
are embracing and adopting the various new manufacturing concepts like 5S, Kaizen, Poka Yoke, SMED,
DMAIC analysis etc.
This paper discusses the SMED concept and methodology as customized for reduction of style changeover
time in garment manufacturing industry and demonstrates a live case that reduced style change over time. The
result achieved showed considerable reduction in delay arising out of machine setting time, batch setting time
and demonstration delay.
Keywords: SMED, Style Change over, Garment industry, Manufacturing
Prediction of Life of Punches of Compound Die Using Artificial Neural Network
1,2
Sachin Kashid1 and Shailendra Kumar2*
Department of Mechanical Engineering, S. V. National Institute of Technology, Surat-395007, India,
E-mail1: [email protected], E-Mail2*:[email protected]
In this paper, research work involved in the prediction of life of punches of compound die using artificial
neural network (ANN) is presented. The parameters affecting life of punches of compound die such as size and
material of punches are investigated through Finite Element (FE) analysisand the critical simulation values are
determined. Based on FE analysis results, S-N approach is used for prediction of number of cycles of punches.
The number of cycles gives the number of sheet metal parts that can b produced with these punches before
their failure.The ANN model using MATLAB is trained using the results of FE analysis. A three layer neural
network is used for development of this model.The developed ANN model predicts the life of punches of
compound die in terms of number of sheet metal parts.The proposed ANN model is tested successfully on
different punches of compound dies used in sheet metal industries.A sample run of the proposed ANN model is
also demonstrated in this paper.
Keywords: Punches of compound die, Artificial Neural Network (ANN), Finite Element Analysis, Sheet metal
Industries
Integrated Decision Making in Supply Chain Management and its Relevance to
Industrial Practice
Amandeep Singh1 and Sandeep Singhal 2*
Department of Mechanical Engineering, NIT Kurukshetra, Kurukshetra, Haryana, India-136119
2*
Department of Mechanical Engineering, NIT Kurukshetra, Kurukshetra, Haryana, India-136119
1*
Supply chain management is one of the prime business strategy opted by many organization, therefore it is
essential to take suitable decision in supply chain. It has always been the intention of supply chain engineer to
invent or produce the best product possible and in the best possible way. Many design techniques have been
introduced over the course of decades that try to fulfill this intention. Unfortunately, no technique has
succeeded in combining decision making on supply chain considering the supply chain objectives as well as
the corporate strategy. This paper not only defines the concept of Integrated Decision Making in Supply Chain
Management but will also evaluate its relevance industrial practice by comprehensively reviewing Decision
Making and Supply Chain Management literature. An efficacious decision making model for supply chain
management is developed in this paper by modifying “ Robin’ s model for decision making” . A case study of a
firm that is a leading brand in beverage industry is presented to better illustrate the concept and theme of the
model and their treatment in industrial practice. Based on our research, the model so developed is used to
provide the best possible integrated decision making in solving supply chain troubles considering the supply
chain objectives as well as the corporate strategy.
Keywords: Decision Making, Supply Chain Management
Impact of Reconfiguration Effort on Reconfigurable Manufacturing System
1*
K.K. Mittal and 2P. K. Jain
Reconfigurable Manufacturing System (RMS) is the state of art technology providing the functionality and
capacity that is required, when it is required. The Reconfigurable Machine Tool (RMT) plays an important role
in the accomplishment of this objective through their modular structure consisting of basic and auxiliary
modules. The RMTs can perform various types of operations in their present configurations and their
functionality can further be altered by just changing their modules. A part can be processed by many feasible
configurations of the RMS in such type of environment. In the present research work the impact of
Reconfiguration Effort (RE) have been analyzed with proper illustrations. The study reveals that the RE has a
great potential in handling the RMS optimization in the planning horizon.
Keywords: Reconfigurable Manufacturing System (RMS); Reconfigurable Machine Tool (RMT);
Reconfiguration Effort (RE); Configuration
Application of Grey based decision making approach for lean tool selection
Adarsh Kumar Singh1, S Vinodh2* and KEK Vimal3
1
National Institute of Technology,Tiruchirappalli, 620015, E-Mail:[email protected]
2*
3
Manufacturing is the addition of value to goods and services during transforming for satisfying human needs.
Each lean tool such as 5S,Value Stream Management (VSM), Total Productive Maintenance (TPM) etc. helps
in elimination of waste and streamlining the process. Decision making for selection of lean tool suitable for an
organization is a major obstacle. The decision with regard to which tool is most applicable for a manufacturing
organization is required by an organization to exploit the maximum benefit.This problem involves evaluation
of lean tools along a set of criteria to identify and prioritize the lean tools. In this paper, grey method is applied
for decision making with regard to lean tool selection. Lean tools are the set of alternatives which are evaluated
along a set of subjective criteria. Grey approach enabled in determining suitable lean tool by evaluating along a
set criteria. A set of prospective lean tools were selected and evaluated along twelve dimensions.Thus the set of
five alternatives were evaluated along the twelve attributesfor selection of appropriate lean tool. The subjective
views of experts were obtained to establish the relationship between alternatives and attributes. The lean tools
were ranked with aid of Grey method along a set of criteria. The outcome of the study will enable the decision
maker for appropriate lean tool selection in a grey environment.
Keywords: Lean Manufacturing, Lean tools, Grey method, Decision making
A Green Process Planning System
Mousumi Gogoi1and Manjuri Hazarika2*
2*
E-mail:[email protected],2*[email protected]
1
The worldwide demand for energy has increased manifold in the last two decades. For example, manufacturing
industry alone consumes one third of the world’ s energy. Innovating new methods of reducing energy
consumption is an important issue drawing global attention. In this work, a green process planning
methodology is developed for machining prismatic parts where the alternative process plans can be evaluated
to ascertain their green quality. An expert system is used for developing the process planning module. Given
the information about different features present in a part, machining operations, machine tools, cutting tools
and material properties as input, the expert system automatically gives alternative process plans for machining
the component. The system is capable of evaluating the green quality of the alternative process plans in the
green criteria evaluation module regarding specific energy consumption, machining time, use of green material
and material consumption. The performance of the green process planning system is validated on a variety of
prismatic parts and agreeable results are obtained.
Keywords: Green process planning, prismatic part, expert system, specific energy, MRR
Application of remanufacturing principles to an automotive engine valve component
Manjunatheshwara K J1, S Vinodh2*and Vimal KEK3
1
Department of Production Engineering, National Institute of Technology, Tiruchirappalli-620015.
2*
3
With a motto to introduce concept of remanufacturing in a component manufacturing industry against the
belief that remanufacturing is not implementable in such industries, an attempt has been made to modify a
component design such that the product is transformed into assembly of parts and thus facilitating
remanufacturing. A case study was conducted in an Indian automotive engine valve manufacturing
organisation. The reengineering study identified the potential of using an alternative design to facilitate
remanufacturing of automotive engine valves. Further sustainable analysis of optimised design also has been
conducted.
Application of S-LCA methodology for assessment of automobile organization
Vimal K. E. K.1 and S. Vinodh2*
National Institute of Technology, Tiruchirappalli– 620015, India
2*
National Institute of Technology, Tiruchirappalli – 620015, India
1
Sustainable development is defined as “ meeting needs of the present without compromising the ability of
future generations to meet their needs” . Sustainable development can be broadly classified into environment,
economy and society. Unlike, environmental and economic perspectives, social perspectives were not
established. Social sustainability assessment cannot be generalized as environment or economy mainly because
it varies with respect to people and culture. Even though, UNEP/SETAC proposed a widely accepted
methodology for Social Life Cycle Assessment (S-LCA), it lacks with consensus characterization model. In
this study, AHP-MGF based characterization model is proposed for assessment of social performance using SLCA framework outlined by UNEP/SETAC. With the developed characterization model and scoring pattern, a
case study has been conducted in automobile organization located in Tamil Nadu.
Keywords: Sustainability,S-LCA; Characterization model; Automobile organization.
A Novel Cell Formation Technique in Cellular Manufacturing System Based on
Production Factors
Tamal Ghosh1*, B. Doloi2 and Pranab K Dan3
Production Engineering Department, Jadavpur University, 188, Raja S.C. Mallick Road, Kolkata 700032.
2
Production Engineering Department, Jadavpur University, 188, Raja S.C. Mallick Road, Kolkata 700032.
3
Department of Industrial Engineering, West Bengal university of Technology, BF 142, Sector 1, Salt Lake
City, Kolkata 700064.
1*
The objective of this article is to exploitrelative machine utilization percentage and machine utilization while
designing efficient manufacturing cells in Cellular manufacturing (CM). This production factorsare rarely been
utilized collectively while designing efficient cells in past CM literature. The proposed model not only
minimizes the material handling cost but also maximizes the machine usage in a cell.A novel performance
measure termed as Reformed Grouping Efficiency (RGE)is also introduced to verify the goodness of the
achieved solutions. The proposed technique can be substantially handy to the production or operational
personnel who are believed to decide the appropriate cell configuration on shop-floor.
Keywords: Cell Formation, Machine Utilization, Cellular Manufacturing System,Performance Measure
A comparative study on the reflectivity of metallic mirrors finished by deterministic and
random processes
Anuj Sharma1*,Prabhat Ranjan2, D. Datta3 and R. Balasubramaniam4
1*
HomiBhabha National Institute, Mumbai-400094,
Email1*: [email protected].
2,3,4
Bhabha Atomic Research Centre, Mumbai-400085
2
Email :[email protected](Email3: [email protected], Email4: [email protected]
Advanced manufacturing has reached the level of finishing the metallic& non-metallic surfaces to nanoand
sub-nanoregimes. Metallic mirrors finished in this regime are finding their application in visible range and near
infra-red optics. There are basically two types of methods by which the metallic mirrors are finished viz.
deterministic nano-regime machining and random finishing. The present study investigates the behaviour of
reflectivity pattern for various wavelengths of incident light on two surfaces generated by these methods and
discusses about the range of wavelength for which the surface can be used as a reflective mirror. This paper
also explains the difference in reflectivity pattern caused due to nano-irregularities present on the two surfaces
due to the process characteristics. One simple model has also been used to confirm the experimental results.
Alternatively, this study also expects the scope of predicting the surface characteristics by using the reflectivity
spectrum.
Keywords: Nano-regime machining, DTM, CMMRF, optical reflectivity.
Identification of Pressures, Barriers and Drivers for the Implementation of Green
Supply Chain Management
M. Deepak1*, A. Noorul Haq2 and K. Mathiyazhagan3
Department of Production Engineering, National Institute of Technology, Tiruchirappalli- 620 015.
2
Department of Production Engineering, National Institute of Technology, Tiruchirappalli- 620 015.
3
Department of Mechanical Engineering, ITM University, Gurgaon, Haryana – 122017.
1*
Green supply chain management (GSCM), a cross-disciplinary field has grown in recent years with increasing
interest from both academia and industry. GSCM considers emphasizing environmental issues in Traditional
Supply Chain Management (TSCM), in both upstream and downstream business enterprises. Due to the new
trends in global warming, environmental sustainability has become a greater concern among the organizations
and enterprises globally. Several developed nations have uncompromising environmental regulations which
lead industries to adopt environmental friendly strategies thereby reducing their overall carbon footprint. In
recent times academicians and practitioners have generated interest in the adoption GSCM practices for
reducing carbon footprints and increasing environmental performance. But adoption of GSCM practices in
industries is challenging and needs more investigation. Generally, industries are less willing to adopt GSCM in
their TSCM without any kind of pressures. Consequently they face more barriers during the adoption of
GSCM. After notable pressures and barriers from external sources are identified, industries started adopting
GSCM practices. For this GSCM to be a sustainable one it is essential that it is supported by various potential
drivers. The objective of the paper is to identify the important pressures, barriers and drivers for GSCM
adoption in Indian automotive sector context from the available literature. The important pressures, the
hindering barriers and the efficient drivers are then identified using Analytical Hierarchical Process (AHP)
approach.
Keywords: Green supply chain management, Indian automobile sector, Analytical Hierarchical Process
A New Hybrid Approach to Recognize Machinable Features of Prismatic Parts from
STEP AP 203 File
Bitla Venu1, Venkateswara Rao Komma2* and Deepanshu Srivastava3
Department of Mechanical Engineering, M. N. National Institute of Technology, Allahabad, 211004.
Email: b.venu1973@ gmail.com
2*
3
1
Feature Recognition (FR) plays major role in engineering significance of a part model and serves as an
important support tool for integrated manufacturing. Feature-based systems typically act as inter link between
the CAD and CAM activities. These systems can be broadly classified into human-assisted feature definition
systems, automatic feature recognition systems and design by features systems. Researchers have come to
realize that the best system architecture for a feature-based system would be a blend of the above mentioned
systems. In this paper, a new hybrid approach is proposed to recognize machinable features of prismatic part
with multiple features on different faces, which is represented in Standard for Exchange of Product Model
Data (STEP) AP 203 file format. The hybrid approach uses syntactic pattern recognition, graph based feature
recognition and other heuristics to recognize the machinable features of prismatic parts. The product model
data represented in STEP AP 203 format is accessed through Java Standard Data Access Interface (JSDAI).
Feature recognition is performed in two stages. In the first stage, syntactic pattern recognition method is used
to recognize simple orthogonal features. In the second stage, graph based method is used to recognize the
remaining features, which were difficult to recognize with the syntactic pattern recognition method. Other
heuristics are also used in both the stages to recognize the feature.
Keywords: Feature, STEP, Prismatic, JSDAI.
STEP-Based Feature Recognition of Orthogonal Primitives of Prismatic Parts
Deepanshu Srivastava1, Venkateswara Rao Komma2* and Bitla Venu3
2*
3
1
Standard for Exchange of Product Model Data (STEP) is being used as one of the effective neutral formats for
exchange and sharing among different CAD systems. STEP also helps in integrating CAD/CAM system, so
that the total manufacturing time and cost is reduced with increased product quality. Feature is the term used in
manufacturing that defines geometric, topological and surface information of the product model. Feature
recognition is the identification of features so that CAD can be integrated with CAM.
In this work, product model information is extracted from STEP text file (AP203) with the program developed
in Java programming language. Further, a hybrid approach is used for recognition of features in the product
model. In the hybrid approach, Attributed Adjacency Matrix (AAM) and a modified syntactic pattern approach
are combined in feature recognition. In the present work, the scope is limited to identify orthogonal primitives
of prismatic parts only. In this work, syntactic pattern approach is modified by replacing the conventional
alphabets with numbers in the pattern string. The sum of the numbers used in pattern string and number of
concave edges (extracted from AAM) are used for recognizing the features. The working of the developed Java
program is demonstrated by applying on the STEP AP203 files of sample prismatic products which contain
different orthogonal primitives such as through slot, through step, blind step etc.
Keywords: STEP, AAM, Syntactic pattern recognition.
Supply Chain Complexity: Challenges and Future Research Directions
Kavilal E.G.*1, S. Prasanna Venkatesan2 and Harsh Kumar K.Dadhaniya3
Department of Production Engineering National Institute of Technology Tiruchirapalli,Pincode-620015.
2
3
1*
The supply chain complexity is a state in which the variety, uncertainty and connectivity prevailing in supply
chain raise to an uncontrollable manner. The supply chain complexity (SCC) will have negative consequences
on the performance of the supply chain. To effectively manage the SCC researchers are developing models and
methods to identify, prioritize and manage the supply chain complexity drivers. The review articles in SCC are
limited in the literature. In this research, papers published during 1998-2014 in refereed journals in the area of
SCC are reviewed. The challenges and research issues related to SCC are highlighted. A quantitative data
analysis software is used to justify the identified research gaps.
Key words: Supply chain complexity, Lliterature review, Complexity drivers
An Assessment of Sustainable Supply Chain Using MCDM
SivakumarK1*, Jeyapaul R2 and Parthiban P3
1*
Department of Production Engineering,National Institute of Technology, Tiruchirappalli-620015,India.
2
,Department of Production Engineering, National Institute of Technology, Tiruchirappalli620015,India,Email:[email protected]
3
Department of Production Engineering, National Institute of Technology, Tiruchirappalli620015,India,Email:[email protected]
Sustainable development (SD) was placed centrally onto the international agenda by the Brundtland
Commission on Environment and Development (WCED 1987), which introduced the oft-quoted statement that
sustainable development is ‘‘development that meets the needs of the present without compromising the ability
of future generations to meet their needs’ ’ . In recent years, sustainable development gains importance across
the supply chain. Sustainable supply chain management has emerged as an important organizational
philosophy to reduce environmental risks without compromising economic and social objectives. In order to
evolve an efficient and effective sustainable supply chain, Sustainable supply chain management (SSCM)
needs to be assessed for its performance. The composite sustainability performance index can showswhich
dimensions of sustainability performance need to be improved based on the impact(positive or negative) to the
company and also helps in identifying whether the company is moving either towards or away from SD. With
the identified indicators, Composite sustainability performance Index (CSPI) can be computed by using
analytical hierarchy process (AHP). The proposed methodology has been demonstrated with case study.
Keywords:Supply Chain; Sustainable development; Composite sustainability performance index; Analytic
Hierarchy Process
Optimization of Flexible Flow Shop Scheduling with Sequence Dependent Setup Time
and Lot Splitting
Vinit Saluja1* and Ajai Jain2
Geeta Engineering College, Naultha,
2
National Institute of Technology, Kurukshetra,
1*
This paper presents optimization of makespan for ‘m’ stages ‘n’ jobs flexible flow shop scheduling problem
with sequence dependent setup time using genetic algorithm (GA) approach. A restart scheme as suggested by
Ruiz et al., 2006 has also been applied to prevent the premature convergence.The paper also assesses the
affect of lot splitting size on makespan. Three case studies are taken into consideration. Five simulation runs
for each lot size are taken and minimum value among them is taken as optimal makespan. Result shows that as
the lot splitting size increases the makespan decreases, reaches minimum value and then increases with further
increase in lot splitting size. Thus there is an optimal lot splitting size which results in the minimum makespan.
For considered case studies, the lot splitting size is three.
Keywords: Flexible Flow shop, Genetic algorithm, Makespan, Lot splitting.
SchedulingA Stochastic Dynamic Job Shop Manufacturing System with SequenceDependent Setup Times
Pankaj Sharma1*and Ajai Jain2
1*
Department of Mechanical Engineering, National Institute of Technology, kurukshetra, India,136119.
2
Department of Mechanical Engineering, National Institute of Technology, kurukshetra, India, 136119.
In this paper, an attempt is made to address a stochastic dynamic job shop scheduling problem with sequencedependent setup times. The objective of the problem is to determine a schedule that minimizes the mean flow
time and mean tardiness performance measures. A discrete event simulation model of the stochastic dynamic
job shop manufacturing system is developed for the investigation purpose. Three dispatching rules i.e. shortest
processing time (SPT), shortest setup time (SIMSET) and earliest due date (EDD) are incorporated in the
simulation model. The simulation experiments are conducted under due date tightness factor of 3, shop
utilization percentage of 90 and setup times less than processing time. The results indicate that the SIMSET
rule provides better performance for mean flow time while the SPT rule provides better performance for mean
tardiness measure.
Keywords: Scheduling, Stochastic dynamic job shop, Sequence-dependent setup times, Dispatching rule
Improvement of Agile Software Production Management Using System Dynamics Model
Pijush Chandra Das1*and U R Dhar2
Department of Business Administration, Gauhati University, Guwahati-781014
2
Royal School of Business, RGI, Guwahati-781035
1*
Production and operations management for any industry is a highly challenging task, to minimize cost, control
overruns, adherence to schedule and improve productivity by optimizing on given resources. Optimizing the
production system of agile software products with frequent change of requirements remains a challenge.
Through system dynamics model we can predict the dynamic behaviour of the agile software production
process including the implications of managerial policies and procedures pertaining to the production of
software. Agile development is one solution to the problem of overly complex methods that has recently been
adopted in the field of software production, and has gained considerable popularity with software producing
organizations. This research investigates how applying system dynamics can help us analyzing the
performance of Agile software production activity and in the long run improves in software production
management. This paper using a system dynamics model portrays some of the dynamic forces directly
impacting the Quality Assurance (QA) activity. The Feedback loop shows how schedule pressures, which arise
when a software project falls behind schedule, can lead to a higher error generation rate. As more errors are
committed, a larger chunk of the available manpower is diverted from development work and devoted instead
to error correction and rework duties. As this happens, the project'
s progress rate drops further, leading to even
greater schedule pressures thus adding to greater cost of poor quality.
Keywords: Agile software development, Software projects, System dynamics, Change request.
Risk Mitigation in manufacturing process through development of 4M Model
1
S Kumar1*and Sharma P2
Management Development Institute, Gurgaon 122007.
2
MSIL, Gurgaon, 122002.
This study deals with the formulation and implementation of a risk mitigation frame work for identifying the
critical nodes of failure, in the manufacturing process at an auto major, and development of an IT system to
track and control these changes. Faced by an increasing level of complaints in the products from customers, the
company decided to conduct a study of the root causes of the major problems reported by the customers. One
of the main cause of the problem was due to unapproved 4 M (Man, Machine, Material, Method) changes at
the company’ s plant and the suppliers. The company decided to develop an IT system to track and identify the
changes made on the company’ s shop floor and it’ s suppliers, and to check if the changes had the requisite
approvals from the process owners.
Rather than designing a system to only track 4 M change approvals, the company decided to initiate the
implementation of a customer facing risk mitigation framework, through the IT system. To identify the critical
nodes of failure in the process, an FMEA (Failure Mode and Effect Analysis) approach was used and RPN
(Risk Priority Number) was be estimated for these nodes using field failure data over a period of time.
Tracking of changes using an IT based 4 M framework , helped in checking the unapproved changes and thus
reducing the variability in the manufacturing process. Traceability of these changes also improved, both
internally and with suppliers.
Keywords: risk mitigation, 4 M framework, Traceability of changes, FMEA, RPN
Knowledge transfer, process fit and other issues in ERP implementation in Indian SME
1
Sanjay Kumar1*
Management Development Institute, Gurgaon, 122007.
The paper describes the attempt of an Indian SME firm to develop an information system, based on an ERP
system, to support the growth plans of the firm. The prior experience of the firm is limited to desktop based
stand alone inventory control and accounting systems. The firm hires consultants for guiding the
implementation. The paper uses available literature on ERP implementation to develop hypothesis about key
variables in ERP implementation, such as change management, project management, and knowledge transfer
from consultants. These hypothesis are then tested along with the hypothesis that the overall ERP
implementation is ‘successful and beneficial’ to the company. The case highlights the problems and impact of
lack of IT domain knowledge and the resulting effects on change management, organizational domain specific
knowledge, project management etc. and shows how this correlates with a poor ERP implementation.
Keywords: Knowledge transfer from consultant, ERP, Process fit, Package functionality, Change management,
project management
A Case Study of Six Sigma and its Competitive Advantage in Indian Industries
Parvesh Kumar1, Sandeep Singhal2 and Jimmy Kansal3*
DepartmentMechanical Engineering, NIT Kurukshetra, Haryana, India, Pin: 136119,
[email protected]
2
Department Mechanical Engineering, NIT Kurukshetra, Haryana, India, Pin: 136119,
[email protected]
3*
Department of Mechanical Engineering, NIT Kurukshetra, Haryana, India, Pin: 136119, Scientist, Snow &
Avalanche Study Establishment, DRDO Chandigarh, ([email protected])
1
Globalization and instant access to information, products and services has in fact made the whole world so
dynamic that it is very difficult to survive without imbibing innovations in work practices and to gain
competitive advantage. It is therefore envisaged that current policy changes in the economy and society should
be carried out in accordance with the principles of sustainable development. The organizations should create
the way for a balanced and integrated approach in terms of economic, social, political, environmental and
security interests. One of the major tools used in practice to stay ahead and near perfection, is Six Sigma,
whose implementation has been gradually promoted in business. The involved employees represent the most
important asset for continual improvements. Focusing on customers, processes and staff makes Six Sigma a
way of building and developing a new corporate culture. This paper examines the benefits, and challenges of
six sigma practices and identifies the key factors influencing successful six sigma project implementations.
Keywords: Six sigma, Project management,Organizational culture, Quality
Application of Lean Principles to Reduce the Non-Value Adding Transportation
Activities in a Rubber Components Manufacturing Industry
K. Balaji1 and V. S. Senthil Kumar2*
1
Department of Mechanical Engineering, CEG, Anna University, Chennai, 600025, India.
2*
Department of Mechanical Engineering, CEG, AnnaUniversity, Chennai, 600025, India.
The Automobile rubber components manufacturing is a mass production process with high operational and
inventory costs. In the competitive manufacturing sector, industries are forced to produce products with a high
variety of components at reduced cost and with improved quality products. The excessive operational and
inventory costs and wastes result in high product cost and losses in the profit. So, the small and medium scale
rubber component’ s industries are trying to implement the Lean concept in their operations, in order to survive
in the competitive global market. The ultimate aim of this research is to evaluate the possibility of reducing the
operational and inventory wastes, using lean manufacturing practices. This paper orients towards identification
and elimination of wastes in rubber component’ s manufacturing industries, using lean principles. This
approach is also focused on the reduction of non-value adding transportation activity by properly modifying
the warehouse layout, using the spaghetti diagram, and provides the proper ergonomics to the workers.
Keywords: Rubber components manufacturing industry, Non-value adding activity, Lean principles.
Integrating Quality Aspects in Design and Manufacturing of Optical Alignment System
R.K. Gupta*, S.P. Srivastava, S.K.Yadav and S.B. Jawale
Centre for Design and Manufacture, Bhabha Atomic Research Centre, Mumbai, 400 085
An Optical Alignment System was designed and manufactured at Centre for Design and Manufacture (CDM)
to establish a virtual plane at 85 mm distance from a wall. The virtual plane was used as a reference plane for
aligning various optical components of a laser system, mounted on the wall. The alignment system was
designed to be fixed at both ends of the wall, having 10m length. Various quality aspects were incorporated at
the design and manufacturing stage to meet the final requirements. The paper presents the design and
manufacturing aspects of the optical alignment system, on-site alignment of the system, instrumentation used
for on-site alignment for establishing the virtual plane in desired accuracy.
Keywords:Alignment, Quality, Manufacture, Alignment Telescope.
Understanding Different Stakeholders of Sustainable Product and Service Based Systems
using Genetic Algorithm for Sustainable Manufacturing
Sameer Gupta1*, Prabir Sarkar2 and Ekta Singla3
1*
SMMEE, IIT Ropar, 140001.
2
3
To have a sustainable product or service, product and service systems must equally satisfy all the three
stakeholders of sustainability: people, planet and profit generated by the companies. However, if often not the
case; this interest of the planet as a stakeholder is often ignored by the other stakeholders. Government tax
incentives could act as an enabler to mitigate this difference. In this work, this issue is explored and presented
through the development of a strategy to optimize the needs of various stakeholders in selecting the right
solution satisfying the needs of users. We develop equations to express the three Ps of sustainability so as to
find out appropriate government incentives, as tax that could be left on people and product manufacturing
companies to make products and services more sustainable. The multi-objective problem is formulated as an
optimization problem and solved using Multi-Objective Genetic Algorithms (MOGA).
Keywords: Genetic algorithm, Resources, Sustainability
Integrated Approach for Job Scheduling and Multi-Component Maintenance Planning in
a Production System
Sandeep Kumar1*, Bhushan S. Purohit2 and Bhupesh Kumar Lad3
1*
Discipline of Mechanical Engineering, Indian Institute of Technology Indore,
2
3
Shop floor level operations planning significantly affect the production system performance. Traditionally, in a
production system, maintenance planning and production scheduling have been considered and optimized
independently. However, these two aspects of operations planning do have an interaction effect on each other
and hence need to be considered jointly for improving the system performance. Current paper proposes joint
optimization of job scheduling and maintenance planning for a multi component machine in a production
system. Multiple jobs having different processing time and delivery dates are considered for
scheduling.Minimization of total cost of maintenance and production is used as the objective function for the
joint optimization problem. Approach is illustrated with the help of an example. Simulation based genetic
algorithm optimization technique has been used to find the optimal solution. The result is compared with the
Earliest Due Date (EDD) sequencing results. It is concluded that the joint consideration of maintenance and
production sequencing results into better system performance.
Keyword: Integrated planning, Job scheduling, Maintenance planning, Simulation
Perceptions of Manufacturing Industries in Adopting Third Party Logistics Providers –
An Empirical Study
P.Vivekanandhan1*, Karthik Subramanian2and Ashwin Vijayakumar3
1
Department of Metallurgical & Materials Engineering,
National Institute of Technology, Tiruchirappalli - 620 015, India.
2
Department of Electrical & Electronics Engineering,
3
(
SRM Easwari Engineering College Chennai 600089, India.
*E Mail: [email protected]
Manufacturing Industries are increasingly looking to optimize their supply chain efficiency to improve
functionality that leads to achieving higher profits and productivity. It is being considered as a primary
component in every manufacturing organization to ensure simpler flow of materials, communications,
inventory, transportation, production without any interruption. The concern over SCM is important in
manufacturing industries and greater efforts are being taken to strengthen their supply chain system either by
recruiting supply chain experts or by outsourcing management of the supply chain to third party logistics
companies for one or more factors. In the past decade, it has been observed that the inclination of large number
of manufacturing companies on Third Party Logistics (3PL) have notably increased and the perception for
outsourcing varies amongst the Industry. In this work, we made an attempt to study the perceptions of
manufacturing industries ranging from small scale to large-scale through feedbacks on key performance
metrics that consists of the core operations and management activities with a third party logistics company. A
questionnaire, encompassing all key performance metrics (independent variables) along with attributes that
depend upon the respective Non-independent variable was framed and feedback was validated by the experts
from the Industries and premier institutions. The questionnaires were issued to more than 150 companies and
120 valid responses were recorded from the employees ranging from junior level to apex level. The feedback
data were validated using data validation tools such as ANOVA, MATLAB and appropriate data simulation
was made on parameters, both dependent and independent variables. It was observed that the perceptions on
adopting 3PL varies with different performance metrics like cost associated with transit, function, value added
services, inventory etc. The results reveal that the key perception is not similar in all the cases and the
importance of metrics varies among the industries based on their investment, asset, requirement and number of
clients.
Keywords: Manufacturing Industries, Perceptions, Third Party Logistics, Supply Chain Management
Group Technology in Design of Manufacturing Systems- A Review
Kamal Khanna1*, Gazal Preet Arneja1 and Rakesh Kumar2
1*
Punjab Technical University, Kapurthala, Punjab-144601,
1*
2
Shaheed Bhagat Singh State Technical Campus, Ferozepur, Punjab-152004
One of the most significant changes in the global economy over the last few decades is the shift of power, in
shaping the market demand from producers to consumers. In the ever growingly competitive environment,
manufacturers are forced to continuously respond to market changes for their survival. The pressure of
competitive pricing, short delivery dates, and high customization has shifted the manufacturing system design
emphasis to flexibility and responsiveness. It has reduced traditional manufacturing systems to sub-optimal
and paved the way for newer ideas of technical and managerial innovations. A number of newer manufacturing
system paradigms have emerged over the years to cater to these modern day manufacturing challenges. Group
Technology, the management philosophy of handling common problems together, has found central place in
most of these paradigms. The present paper is an attempt to provide a succinct review of the literature on this
issue in three parts. First part deals with review of drawbacks of various classical manufacturing system
paradigms. In the second part the emergence of various modern manufacturing system paradigms is
chronologically discussed in the light of drawbacks of classical paradigms. The second part will also attempt to
bring out how Group Technology has emerged as the backbone of all these paradigms. In the third part of the
paper, an exhaustive review of the research works on part classification (and/or machine groups’ formation)
used across various modern manufacturing systems has been presented. Literature is classified chronologically
as well as on the basis of various approaches such as coding and classification, clustering, knowledge based
systems, heuristics, soft computing, simulation etc. The paper also attempts to classify the literature on the
basis of parameters used, objectives considered and the focus orientation. Finally, it sums up with a vision for
future research in this area.
Keywords: Group Technology, Manufacturing Systems
Improved Music Based Harmony Search Algorithm (IMBHSA) for solving Job Shop
Scheduling Problems (JSSPs)
1*
M.Hymavathi1*and C.S.P.Rao2
Department of Mechanical Engineering, Bengal College of Engineering and Technology, Durgapur West
Bengal – 713209, India.
2
Department of Mechanical Engineering, National Institute of Technology,
Warangal, Andhra Pradesh – 506004 India.
In this paper, a new meta-heuristic solution approach for Multi-objective Job Shop Scheduling Problems
(MOJSSP) is presented.An Improved Music Based Harmony Search algorithm (IMBHS) is a recently
developed algorithm which is conceptualized using the musical process of searching for a perfect state of
harmony. It uses a stochastic search instead of a gradient search. Music Based Harmony Search algorithm
(MBHS) and an Improved Music Based Harmony Search (IMBHS) algorithm were proposed to minimize the
Makespan, Minimize the Mean flow time and Minimize the Mean Tardiness. The results are compared with
Bench Mark Solutions (BKS) and it is found that both the methods performed better in terms of the quality of
solution but in few problems IMBHS is performing better when compared to the MBHS method and BKS
solutions. The results obtained in this study have shown that the proposed IMBHS algorithm can be used as a
new alternative solution technique for finding good solutions to the JSSPs.
Keywords: Metaheuristics, Job Shop Scheduling, Improved Music Based Harmony Search
Development of New Paradigms for Job Shop Scheduling Problems
1*
M.Hymavathi1*and C.S.P.Rao2
, Department of Mechanical Engineering, National Institute of Technology, Warangal, Andhra Pradesh –
506004 India.
2
Department of Mechanical Engineering, National Institute of Technology,
Warangal, Andhra Pradesh – 506004 India.
In this paper, various new meta-heuristic solution approaches for both mono and multi objective Job Shop
Scheduling Problems are presented. Various methods have been used in the field of Job Shop Scheduling. The
methods used for JSSP are generally divided into two broad categories: traditional approaches and non
traditional approaches. More focus on the application of Non Traditional methods for JSSP is increasing
compared to traditional techniques. For the same cost and time non traditional methods yeild better solutions
compared to traditional methods. There are fewer applications of Particle Swarm Optimization (PSO) and
Hybrid Particle Swarm Optimization (HPSO) for JSSPs.There are fewer applications of Artificial Immune
Algorithms (AIA) for JSSPs. The power of AIA is not fully exploited for JSSPs. Bacterial Foraging
Optimization (BFO) algorithm have very few instances of apllications to JSSPs. Invasive Weed Optimization
(IWO), Music Based Harmony Search (MBHS) were used to address several other engineeing optimization
problem and they were not used for JSSPs.
Keywords: Bacterial Foraging Optimization, Invasive Weed Optimization, Music Based Harmony Search
System Dynamics Model in the Analysis of Manufacturing Defects and Process
Improvements
B. Chowdhury1*, S.K. Deb2 and P.C. Das3
Department of Mechanical Engineering, Assam Engineering College, Guwahati -781013.
2
3
Department of Business Administration, Gauhati University, Guwahati – 781014.
1*
Manufacturing of a product in a product line involves various phases - design, fabrication, assembly and
finally manufacture. Again each of these phases may yield defects which cannot be ignored. This is because
defects play one of the foremost roles in defining productivity of a manufacturing organization. Hence their
analysis and subsequent elimination or reduction is of extreme importance which otherwise tend to shoot up
the cost of poor quality. Different organizations deploy different traditional statistical tools to perform defect
analysis. But owing to dynamicity of today’ s business with respect to production environment and its product
lines, it is essential that these defects be analysed with a dynamic tool like system dynamics. Hence in this
paper an attempt has been made to specifically study and analyse a list of production defects using system
dynamics models. Using the models, solutions for process improvement to reduce defects have also been
proposed. For the purpose of the study, defects obtained during the manufacturing of thermoformed
refrigerator liners have been taken.
Keywords: Process improvement, manufacturing defects, system dynamics.
Development of SPM for Automation in Sheet-Metal Disc Teeth Cutting Operation
Chetan Mahatme1*, Sachin Mahakalkar2 and Jayant Giri3
1*
YeshwantraoChavan College Of Enggineering, Nagpur, 440010, E-Mail: [email protected]
2
YeshwantraoChavan College Of Enggineering, Nagpur, 440010, E-mail: [email protected]
3
YeshwantraoChavan College Of Enggineering, Nagpur, 440010, Email:[email protected]
This paper discusses the development of an automated loading and unloading system for sheet-metal disc teeth
cutting operation on a power press. Presently the operation under consideration is manual. The worker
manually picks the disc from the input bin and places it onto a press bed for teeth cutting and after completion,
removes the disc and places it into an output bin. Because of such repetitive task, the worker is prone to
various musculoskeletal disorders (MSDs) and cumulative trauma disorders (CTDs). If the cycle time is further
reduced, there will be gain in production quantitatively, but the efficiency of the worker will further reduce and
there will be chances of fatal injuries. For studying the ergonomic conditions of the worker, a detailed RULA
and REBA analysis of the worker is carried out. On the basis of ergonomic analysis results, an alternative to
the manual operation, a more sophisticated automated loading and unloading system is suggested. The viability
of the suggested system is checked through simulation and FEM analysis. A scaled prototype model of
proposed system is also developed and tested. The software used for RULA analysis, CAD model development
and simulation is CATIA V5R19. For REBA analysis REBA assessment worksheet is used.
Keywords: RULA, REBA, Modelling, Simulation
Paper #AIMTDR-P0552(Poster)
Productivity Improvement through Modular Line in Garment Industries
B. Sudarshan 1 and D. Nageswara Rao2
Centurion University of Technology and Management, Paralakhemundi,761200.
2
Centurion University of Technology and Management, Paralakhemundi-761200.
1
The readymade garment (RMG) industries produce momentous quantities in shorter cycle times. Garment
product is highly correlated with high level of productivity as sewing line is balanced in shorter possible time
and effective way for each style of garment and required quantity. The focal constraint against the higher
productivity is the difference in individual capacity leading to improper line balancing and thus a bottle neck.
This paper is based on an effective layout model to clear the bottleneck process through benchmark capacity
leading for a balancing process using two separate concepts of manufacturing processes- modular line and
Traditional system both together. The results show that this balanced layout model has increased the efficiency
by 22%, and labor productivity by24%,based on the two folded objective of investigation of value stream
mapping in existing production line and to altering the same with new cellular or Modular based layout. Work
in progress (WIP) will be analyzed in all sewing room production lines to realize the significance.
Keywords: Productivity, Value Stream Mapping, Modular manufacturing, Work-In-Process
Status of implementation of Lean manufacturing principles in the context of Indian
industry: A Literature Review
A. P. Chaple1*, B. E. Narkhede2andM. M. Akarte3
1*
VJTI, Mumbai, 400019.
2
Production Engineering, VJTI, Mumbai, 400019.
3
NITIE, Mumbai, 400087.
Today, principles and practices of Lean manufacturing are widely used by industries to eliminate waste and
make the process more efficient. Lean has been recognized as one of the key approaches in enhancing the
productivity and hence the competitiveness of an organization. This paper presents a review of lean principles
and practices in the Indian manufacturing industries. The paper contributes by identifying enablers & barriers
in implementing the lean principles and practices, methodologies used in leanness measurement of an
organization in the Indian manufacturing industry. Finally, the diffusion of lean in the Indian manufacturing
industries has been given.
Keywords: Lean manufacturing, Leanness, Lean barriers, Lean practices.
Tool Inventory Management Using RFID Technology
1
Ishwar Bhiradi1 and Ajesh J.Pillai2*
Department of Mechatronics Engineering, Manipal Institute of Technology, Manipal,576104,Karnataka.
India. E-mail: [email protected]
2*
Department of Mechatronics Engineering, Manipal Institute of Technology, Manipal,
576104, Karnataka. India. E-mail: [email protected]
Radio Frequency Identification is an emerging technology in the field of manufacturing. RFID can be used for
many features such as in supply chain, job tracking, job order status etc. RFID is divided into 2 main
categories active and passive. Passive RFID tags are used where the distance between the reader and the tag is
minimum (less than 2 meters) and when cost effectiveness is to be considered. But when it comes to active
RFID the distance between the reader and tag can be more than 4 meters but this is an expensive technology
therefore one should always consider effective method for the maximum utilization of the technology. This
research study is mainly focusing on RFID for tool inventory management using active RFID tag. Using RFID
technology one can monitor the tool usage, tool breakage documentation, also tool life and cost of the tool
monitoring can be possible. For the implementation of this technology, one medium scale manufacturing unit
has been taken as study area which includes approximately 25 varieties of tools such as turning, drilling,
threading, grooving, endmill holder etc., each variety has hundreds of quantities. With the implementation of
RFID technology attempt has been made for the establishment of the proper inventory thereby reducing 28%
of reduction in the unwanted expenditure on cutting tools. Through case study discussion this paper
demonstrates the implementation of RFID technology for the betterment tool inventory management in a
medium scale manufacturing unit.
Keywords: RFID Technology, Inventory management, Job tracking, productivity improvement.
Work Measurement Approach for Productivity Improvement in a Heavy Machine Shop
Ishwar Bhiradi1 and B. K. Singh2*
1
Department of Mechatronics Engineering, Manipal Institute of Technology, Manipal, Manipal –
576104,Karnataka. India.
2*
Department of Production Engineering, Birla Institute of Technology, Mesra, Ranchi – 835215, Jharkhand.
India.
*E-mail:[email protected]
Productivity improvement is an everlasting continuous activity in manufacturing. Industries need to develop
capability of coping up with customer demands to deliver quality products on time. Continuous improvement
is the need of the hours which can be achieved by incorporating flexibility in layout, design and processes.
This paper is aimed at improving productivity of mixed model production system of a medium scale
manufacturing industry through work measurement approaches. The work measurement of various elements of
the work cycle has been made on the basis of recommendations of ILO. The work cycles were divided into
small measurable work elements. These elements were recorded on the observation sheet. Observations have
been recorded for different trails to analyse the operation effectively for identification of value-added and nonvalue added element. Productivity improvement of 35% has been shown after elimination of non-value added
elements.
Keywords: Productivity, Work measurement, Machine shop, Mixed model production.
Single Model Assembly Line Balancing for Newly Recruited Employees
1*,2
Sandeep Choudhary1* and Sunil Agrawal2
PDPM Indian Institute of Information Technology, Design and Manufacturing, Jabalpur, 482005.
E-mail: *[email protected], [email protected]
There is a class of assembly line balancing problems in management science that helps finding out the
optimum production rate of the line. In this paper new constraint is developed for the newly recruited
employees that are under training period considering a simple assembly line balancing problem of type-2
(SALBP-2). Further, an algorithm is proposed which will allow the supervisor to take the proper decision
during the allocation of task to the newly recruited employees with the least effect on the production rate.
According to the algorithm, out of the total number of tasks in an assembly line, few tasks are manually
assigned to newly recruited employees and the rest of the tasks are assigned to the senior employees in such a
way that production rate does not suffer. The mathematical model is solved by Branch and Bound method
using Lingo 10 software package.
Keywords: Single model assembly line, Branch & Bound algorithm, Newly recruited employees
Decision Making Using Analytical Hierarchical Process (AHP) for Selection of Best
Suitable Maintenance Method for Multispindle Automat AS32
1
Jayant S. Karajagikar, 2 Bhagwan U. Sonawane
Department of Production Engineering and Industrial Management, College of Engineering, Pune-411005.
2
Department of Production Engineering and Industrial Management, College of Engineering, Pune-411005.
1
A different approach for carrying out criticality analysis and decision making for maintenance is adopted in
this work, carried on an Automat which runs for twenty hours a day. Selecting the problem of choosing an
optimum maintenance mode for machine/ equipment important function components, Reliability Centered
Maintenance (RCM) theories and methods are used to evaluate the fault criticality of the important function
components and confirm the estimating indexes for the maintenance modes and their weight scales, while AHP
[
method is applied to establishing the hierarchy of the important function component maintenance decisionmaking. According to calculating and comparing the resultant weight scales of the maintenance modes for
different important function components, the rational maintenance modes are ascertained and some important
conclusions are found out, which provides a new thought and method for logical decision-making of goodsized complex equipment maintenance. In present case, HMT Gildemeister Multi-spindle Automat AS32
machine tool is considered for the said analysis to find out the critical components and its maintenance
planning.
Keywords: AHP, Maintenance optimization
Comparative Analysis of Manufacturing System Using Cause-Effect Diagram and
System Dynamic Model
B. Chowdhury1* and S. K. Deb2
*Department of Mechanical Engineering, Assam Engineering College, Guwahati -781013.
2
1
Defects that surface during the various phases of a manufacturing system play a significant role in product
development and its sustainability in the market. These defects need utmost attention and extreme analysis for
the latter to happen. Manufacturing industries uses traditional quality control tool namely cause and effect
diagram to analyze manufacturing defects which provide a two way interaction between causes and their
effect. However, the cause and effect analysis is mostly seen to cater to those factors which are responsible for
the intended effects. As a result, the unintended and unanticipated effects hardly surface during the analysis
and are ignored. Again, from the diagram it is not known whether the effects stimulate any cause and affect the
system. To make the analysis more dynamic, tools such as System Dynamics (SD) could be applied which not
only relates to the cause and its effect but also provide feedbacks, thereby giving three dimensions to the
analysis. Hence in this paper an effort has been made to do a comparative study of manufacturing defects using
cause-effect diagram and SD models. To perform the analysis, the defects obtained during the manufacturing
of refrigerator liner have been taken. Causal loop diagram of SD models were generated which relates to the
causes and their effect, and also produce closed loop feedbacks (reinforcing or balancing) which are path
dependent. These feedbacks help to predict the unanticipated effects and hence the behavior of the system.
Accordingly, necessary steps to reduce effects could be taken, which otherwise was not possible with open
looped cause-effect diagrams.
Keywords: Causal loop diagram, Cause-effect diagram, System dynamics, Manufacturing defects.
Paper #AIMTDR-O0635(Oral Presentation)
Optimization of Machining Time using Feature Based Process Planning
Borkar B. R.1*, Puri, Y. M.2,Kuthe A. M.3, Deshpande P. S.4
Department of Mechanical Engineering,Visvesvaraya National Institute of Technology, Nagpur, India,
440010.
2
Department of Mechanical Engineering, Visvesvaraya National Institute of Technology, Nagpur, India,
440010.
3
Department of Mechanical Engineering, Visvesvaraya National Institute of Technology, Nagpur, India,
440010.
1*
4
Department of Computer Science &Engineering, Visvesvaraya National Institute of Technology, Nagpur,
India, 440010.
Planning for machining sequence can be considered as one of the most important functions of manufacturing
process planning. However, less attention has been paid to automation of this function in contemporary
computer-aided process planning systems. This paper describes an e cient algorithm for automatic machining
sequence planning in 2.5D milling and drilling operations. It is programmed in Visual C# and forms the
machining sequence planning module of a CIM system. This module is integrated with a feature-based design
system that determines required machining operations and parameters for each machining operation. This
information is then sent to the machining sequence planning module for determining proper machining
sequence plans for producing the part. The algorithm generates feasible machining sequences and optimizes it
based on machining time. The algorithm results in minimized tool changes
Keywords: CAPP, CAM, CAD, STEP
TPM-A PDCA Approach
P.K. Suresh1*, Mary Joseph2 and Jagathy Raj.V.P3
1
* School of Management Studies,Cochin University of Science & Technology,Kochi-22,Kerala,India.
2
Bharatha Matha Institute of Management, Thrikkakkara, Kochi,Kerala,India.
3
School of Management Studies ,Cochin University of Science & Technology,Kochi-22, Kerala,India.
India as a rising economic power, has not achieved its potential as Technology, Globalization, and
International Competitiveness. Today’ s competition is ruthless and survival depends on the availability of
products and services at low cost, timely delivery, courteous sales and prompts after sales service. The
precision equipment and devices helps in monitoring and controlling raw material quality, consistency and
functional efficiency of equipment and their accuracy, auto operational systems etc minimizes or avoids
defects.But even the maintenance of equipment has become an additional responsibility and maintenance still
depends upon human beings. The concept of Total Productive Maintenance (TPM) meets this need.Total
Productive maintenance (TPM) concept helps for the scientific upkeep of plant and equipments. This study
conducted among selected industries in South India from various sectors which already practicing certain
quality management tools and also done in TPM awarded companies. The relationship between the
implementation factors and performance are analyzed. The P.D.C.A approach in TPM implementation starts
from the initiatives from the top management. Top management has to review the progress of implementation
at frequent intervals and to take proper corrective measures for overcoming the hurdles.
Key words: TPM, Lean, PDCA approach
Mixed-Model Assembly Line Balancing Problem: A Focus on Model Formulation
1*,2
PDPM Indian Institute of Information Technology, Design and Manufacturing,
Jabalpur, 482005.
The objective of this paper is to improve the performance measures of a mixed model assembly line. The
motivation of our work is from the paper by Zhang and Gen (2011). This paper focused on the way of correct
formulation of decision variable, it is the relationship between more than one entities. For this the
mathematical model given by Zhang and Gen (2011) is targeted. Author gives their own mathematical
formulation and hence there mathematical model is solved using branch and bound method by just considering
their one objective function for minimization of cycle time. Later the same mathematical model is
reconstructed in this paper by changing the index of decision variable without changing the mathematical
meaning and has been solved using the same method for the given objective function. Result shows that there
is significant improvement on assembly line when mathematical model reconstructed, as their cycle time (Ct)
is improved by 21.54 min, balance efficiency (Eb)is improved by 1.95 percent and productivity is increased by
17.14 percent.
Keywords: Assembly line balancing, Branch and Bound algorithm, Mixed model
U-line Assembly Balancing for Medium Commercial VehicleEicher Motors Ltd: A Case
Study
1*,2
PDPM Indian Institute of Information Technology, Design and Manufacturing, Jabalpur, 482005.
In this paper simple assembly line balancing problem (SALBP) of assembly plant at Eicher Motors Ltd.
Pithampur, Madhya Pradesh (INDIA) is considered with the objective of minimization of workstation for a
fixed value of cycle time. At present the total tasks assembling the final product (Medium Commercial
Vehicles (MCV)) are distributed among 19 workstations. The number of workstations is identified using
traditional method and is arranged in a straight line layout. This paper attempt to improve the existing
assembly line of Eicher Motors Ltd by minimizing the number of workstations by change its layout to Ushape. The advantages obtained are manifold. (1) The U-shaped layout has 12 numbers of workstations, (2)
The improvement in the following performance factor is also realized (a) Balance efficiency (Eb) and delay (d)
is improved by 31.85 percent, (b) labor productivity is improved to 58.55 percent.
Keywords: Straight layout, U-shape layout, Branch & Bound algorithm
Implementation of Six- Sigma Methodology for Improvement of Process Yield by
Reduction of Rejection (For %) in a Manufacturing Process
S. Chandra, B. Doloi, and B.K. Bhattacharya
Jadavpur University, Kolkata, 700006, E-Mail:[email protected]
Jadavpur University, Kolkata, 700032, E-Mail: bdoloionline @rediffmail.co
B.E.S.U, Howrah, West Bengal, 711103, E-Mail:[email protected]
Continuous Improvement is one of the prime factor for effective implementation of Total Quality Management
in an organization .Continuous improvement encompasses the involvement of people and systematic method
for tackling the problems related to the quality of product /services and the processes. There are various
methods and techniques available for systematic analysis of the problems and also induce solution of the same.
This paper deals with the problem of low yield / higher level of rejection in Glass Neck ( used as a part of
Picture Tube in TV industry ) forming process and improvement of the yield of output through systematic
involvement of people as a group and adopting Six- Sigma methodology. As per the methodology of Six
Sigma the following phases were followed for the improvement project to reduce the FOR of the process.
Define Phase: The project has been defined as reduction of % Fall of Rate (Rejection of the process) of Glass
Neck production output through Six-Sigma Methodology. In this industry the rejection of output is expressed
as Fall of Rate (FOR) Measurement Phase: During the period June, July and August, 2012, the data on
rejection have been compiled and the average monthly % FOR found to be 6.34% and the process yield has
been 93.66%. Thus the quality performance level as well as the waste generation is not in good stead. This
indicates poor viability of the process to continue its operation. To make it viable a project team has been
formed to bring down the rejection level to 1, 5% within a period of 4/5 months. Analysis Phase: Analysis on
the reasons of poor performance indicator has been carried out and from this certain reasons contributing major
portion of the rejection have been pointed out as per Pareto analysis. From the major reasons of rejection, it has
been analysed further to find out the possible causes of rejection through Ishikawa Diagram. With the aid of
this diagram, root causes have been pointed out through technical and logical considerations and working
experience. In the next stage, it has been established the sources related to these causes. Implementation Phase:
Based on source analysis the various related factors concerning man, materials and machine are taken up to
initiate action plan for improvement. Action plan has been developed for different stages and actions have been
taken up with proper monitoring. Monitoring of FOR revealed continuous reduction in %FOR from 6.34% to
1% after 4 months and also increase in output Control Phase: To hold the gain through this study, it was
necessary to put in action the control measures at predetermined areas so as to maintain the system as was
planned during the improvement phase At this stage, it has it has been decided to monitor the important control
points to sustain the improvement.After implementation of Six Sigma methodology the following tangible gain
could be achieved Reduction of % of F.O.R. from 6.36% to 1.5%. Hence improvement of yield from 93.64%
to 98.5%. Cost saving was in tune of Rs. 1.3 Crore. Economic viability of the plant could be restored.
Keywords: Six-Sigma, Total Quality Management
Safety management in Manufacturing Industry: A Lean Six Sigma Approach
1
*P. R. Gajbhiye,2 A.C. Waghmare and 3R.H. Parikh
KDKCollege of Engineering,Nag Road,Nagpur, 440009.
2
Umrer College of Engineering, Nagpur Road, Umred ,
3
Bhausaheb Mulik College of Engineering, Butibori, Nagpur
1
The lean manufacturing company under consideration recorded the high accident rates for last few years.
These accidents cause the organization the heavy man-day loss, the production loss and heavy costs of
insurance. The objective of health and safety department at the manufacturing company was to set and improve
accidents prevention system. The paper presents how the six-sigma technique will helps to evaluate the safety
and environmental hazards in performance of organizations. It is observed that the study helped the
management to measure, analyze and improve overall safety plan to protect the life and health of the
employees. The paper discusses real life case where six sigma has been successfully applied at one of the
Indian small scale unit to improve safety in processes. The main aim behind this project lies to overcome those
problems of the industries which are causing loss due to safety. In order to build up system capabilities and
graduate towards higher sigma levels of operation, the backbone exercise of six sigma management system is
reached by carrying out the failure mode effect analysis.
Keywords:Six sigma, DMAIC, Safety, Lean Manufacturing, Defects, Variation, Accidents
Root Cause Analysis of Tong Mark Defect during Material Handling of IF Steel Coils
G. Mathan1, G. Manikandan1* and M B N Raju2
The cold rolled IF coils are usually carried into Batch Annealing Furnace (BAF) for annealing by means of
mechanical tongs.On discharge of coils from BAF, a peculiar type of line marks (surface defect)are appeared
perpendicular to rolling direction on both inner and outer wraps of IF steel coils. These defects are causing
significant appearance problems after painting. In the present work, the morphology of the defect was
examined in detail through characterization by visual inspection andoptical microscopy. Surfacetopography
and residual stress analysis along with Finite element simulation was also performed to understand the
mechanism behind the origin of this line marks. From the study, it is clear that the curvature mismatch between
coil and tong give rise to the origin of this defect.
Key words:Tong Mark, batch annealing furnace, Interstitial Free steel
Parametric Optimization of Machining Parameters using Graph Theory and Matrix
Approach
L B Abhang1 and M Hameedullah2
Mechanical Engineering Dept. Aligarh Muslim University, Aligarh, India
202002, 1*E-mail: [email protected]
This study investigated the multi-performance optimization of turning process for an optimal parametric
combination to yield the minimum cutting forces and surface roughness with the minimum power consumption
using graph theory and matrix approach. The experiments were carried out as per L9 orthogonal array with
each experiment performed under different machining conditions of feed rate, depth of cut and lubricant
temperatures. In GTMA, a performance suitable index evaluates and optimizes the multi-performance
characteristics. It is registered that the performance, for which the value of PSI is highest, is the optimum
choice for the given machining conditions. The index is obtained from the matrix model developed from the
digraphs. Graph theory and matrix approach methodology reveals that a combination of high level of depth of
cut and lubricant temperature along with feed rate in the low level is essential in order to simultaneously
minimize (optimize) the main cutting force, surface roughness and power consumption during steel turning.
Keywords: Graph theory and matrix approach, surface roughness, cutting force and power consumption
Automatic Identification of Cylindrical/Tapered Features from Prismatic Components
Dowluru Sreeramulu1* A. Satish Kumar2 and C.S.P. Rao
Mechanical Engineering Department, AITAM, Tekkali, AP-India, 532201
2
Mechanical Engineering Department, AITAM, Tekkali, AP-India, 532201
3
Mechanical Engineering Department, NIT - Warangal, AP-India, 506004
1*
Automatic identification of different feature from a CAD solid model for downstream applications like process
planning and NC program, greatly contribute to the level of integration. Different data exchange standards like
IGES, DXF, PDES and STEP standards plays an important role to transfer the geometric data between CAD,
CAE and CAM. Among those, the STEP standard comprises both geometric and technological information
including geometry, topology, features, tolerances, surface roughness and material necessary to completely
define a component. For that reason this paper proposes automatic recognition of different cylindrical/taper
features using STEP file. The methodology proposed in this work includes development of an algorithm for
identifying different cylindrical/taper features like cylindrical holes, taper holes, cylindrical protrusions, taper
protrusions and stepped holes in prismatic parts modeled in any CAD software having the STEP out put file
extension. A generalized JAVA program is used to implement the algorithm. Finally this paper also presents
the implementation of the above algorithm for different example parts to demonstrate the application of the
proposed methodology.
Keywords: Cylindrical feature, STEP file, Taper feature recognition.
Comparative Assessment of Primitive Features Machined with Different Diameter End
Mill Tools using Reverse Engineering Technique
Sachin Gupta1* and A. A. Shaikh2
1*
Sardar Vallabhbhai National Institute of Technology, Surat,395007
2
Sardar Vallabhbhai National Institute of Technology, Surat, 395007
Reverse engineering, the latest trend in the industry now a day, is the methodology to construct CAD model
from an existing prototype. It extracts feature information from any product. This information plays an
important role in development of exact replica of part or modifying its design. This paper deals with cases of
spherical cavity and rectangular cavity, to be created with different diameter end mills on CNC mill. Original
CAD model is compared with point cloud data generated by Roland needle scanner with accuracy 200 m, in
order to calculate surface deviation using Pro/Verify. These features are broken down in basic primitives as per
GD&T (Geometric dimensioning and tolerance) and are evaluated in accordance of straightness, flatnessand
circularity. The reverse engineering model is also developed using Creo REX Extension to compare surface
area and volume with respect to original CAD model. This work reports extent of error with aspect of form
attributes. The deviation observed between cloud model and base model is also reported for convergence of
variation in tool diameters.
Keywords: Reverse engineering, Geometric dimensioning & tolerance, Pro/Verify, Creo REX Extension.
Systematically Investigating Literature of Supply Chain Risk Management: A Review for
Risk Prioritization
Surya Prakash1*, Sameer Mittal2, Gunjan Soni3 and Ajay Pal Singh Rahtore4
1*
Malaviya National Institute of Technology, Jaipur, 302017,
2
3
4
In the present time of highly competitive and uncertain business environment, supply chain risks management
(SCRM) is very crucial aspect. The pivotal focus of this paper is to identify dominant risk factors or their
causes for supply chain risk management practices. The cause and effect methodology is used to identify the
set of risk factors in supply chain from literature. For this purpose 343 research articles across six management
science databases have been selected, classified and synthesized. In total 19 risk factors have been identified
through content readingof available research articles. The major contribution of this paper is identification of
most prevalent risk factors in supply chain and their prioritization through analytic hierarchy process (AHP)
approach in a novel manner. This objective of risk dominancy determination is derived by utilizing AHP in a
novel manner. The managers of companies can focus on commanding these risk factors to achieve strategic fit
and reliable risk management for their supply chain operations. (*Corresponding author)
Keywords: Supply Chain, Risk Management, AHP, Risk prioritization
Aero-Engine Compressor Rotor Development through Reengineering based Product
Development Cycle
S. N. Mistry1*, Amar Singh2 and Joseph Shibu .K3
*1
RCMA(E), CEMILAC,Bangalore, Karnataka, India, 560093
2,3
AERDC, Hindustan Aeronautics Limited, Bangalore, Karnataka, India, 560093
Present paper details an aero-engine centrifugal compressor rotor development through reengineering based
product development cycle to
augment in-house technology development
program and to improve the product performance such as fatigue life, efficiency
etc. by usage of superior
material/technology while keeping the overall envelope, mass and center of gravity similar to the existing one.
The four phase product development cycle started with assessment of requirement of the product and
benchmarking where products of similar nature are identified, studied and ideas so developed are utilized for
designing the part. The product development cycle continued through product design which involved design
calculations, modeling, drawing generation and structural integrity evaluation through FE analysis. In the
prototype testing phase of the product development cycle, compressor rotor has been fabricated through
forging route and its structural integrity has been validated through cyclic spin test at its operating speed as
well as 15% and 22% over-speeds in the rig. Satisfactory performance during these tests without any distress
has demonstrated the adequacy of design. The compressor rotor
fitted in
engine
was then
!before " cleared for #
. $roduction of the compressor
is the culminating phase of the product development cycle.
Keywords: Reengineering, Product Development Cycle, Centrifugal Compressor
Enhancing Agility of Supply Chains using Stochastic, Discrete Event and Physical
Simulation Models
Alok K Verma
Old Dominion University, Norfolk, Virginia, USA
Managing supply chains in today’ s distributed manufacturing environment has become more complex. To
remain competitive in today’ s global marketplace, organizations must streamline their supply chains. The
practice of coordinating the design, procurement, flow of goods, services, information and finances, from raw
material flows to parts supplier to manufacturer to distributor to retailer and finally to consumer requires
synchronized planning and execution. Efficient and effective supply chain management assists an organization
in getting the right goods and services to the place needed at the right time, in the proper quantity and at
acceptable cost. Managing this process involves developing and overseeing relationships with suppliers and
customers, controlling inventory, and forecasting demand, all requiring constant feedback from every link in
the chain. First, a survey of existing stochastic models is presented. Base Stock Model and Q (r) models are
applied to three tier single-product supply chains to calculate order quantities and reorder point at various
locations within the supply chain. A computer based discrete event simulation model is created to study the
three tier supply chain and to validate the results from the stochastic models. Results indicate that agility of
supply chains can be enhanced by using the stochastic models to calculate order quantities and reorder points.
In addition to reducing the total cost of inventory, probability of backorder and customer dissatisfaction is
minimized. Results are further validated with physical simulations. Both computer based simulation and
physical simulation demonstrate the improvement in the agility of the supply chain with reduced cost for
inventory.
Keywords: Stochastic inventory models, Base stock model, Discrete event simulation, Physical simulation.
CAD Laboratory
Abstracts of Miscellaneous Papers
Manufacturing Experiences of a High precision Six Axis Parallel Manipulator (Hexapod)
R. K Sachan*, J.J. Roy, H.B Panse and S.B. Jawale
Centre for Design and Manufacture
Bhabha Atomic Research Centre
Trombay, Mumbai - 400 085
Email: *[email protected], [email protected]
Six Axis Parallel Manipulator (Hexapod) is a very high precision robotic platform, having six degree-offreedom of movement. It consists of six motorized actuators, connected between the top moving platform and
the bottom fixed platform. The moving top platform obtains its six degrees of freedom movement from the
combined computed movements of six independent actuators. Travel range along X, Y, Z axis is ± 60mm with
positional accuracy of 20 m. Rotational range about X, Y, Z axis is ±2degree with angular positional accuracy
of 10 Arc seconds. CDM has successfully designed & developed the technology for manufacturing these high
precision robotic platforms. Load capacity of this Hexapod is 1.5 T. The manufacturing of this sophisticated
robotic platform involved machining of precision components like end support Ball units for Actuators,
Actuator Housing & Motor Housing for achieving a very high degree of accuracy in positioning such a big and
heavy structure. The Ball unit & its locating elements were provided with Diamond like coating (DLC) to
reduce friction & improve wear resistance. Destination position of the top plate is fed to a controller pc based
programme in X, Y, Z, %x, %y & %z form. Control system works in closed loop with continuous feedback from
linear sensors and limit switches. This paper disseminates the varied experiences gathered in manufacturing
these very high precision robotic platforms.
Keywords: Parallel Manipulator, Robotic platform, Hexapod, Precision-machining.
Theoretical and Experimental Verification of Vibration Characteristics of Cracked Rotor
System in Viscous Medium
1,2
Adik R. Yadao1*and Dayal R.Parhi2
Department of mechanical engineering, National Institute of Technology, Rourkela, Orissa 769008
2
This paper contains an attempt to evaluate dynamic behaviors of cantilever cracked shaft with mass attached at
the end of the shaft in viscous medium at finite region. In this work theoretical expressions have been
developed for finding the fundamental natural frequency and amplitude of the shaft with attached mass using
influence coefficient method. External fluid forces are analyzed by the Navier Stoke’ s equation. Viscosity of
fluid and crack depth is taken as main variable parameters. Suitable theoretical expressions are considered, and
the results are presented graphically. Further experimental verifications have also done to prove the
authenticity of the theory developed. The work leads to the conclusion that, the variation of parameter of
cracked shaft system makes an appreciable difference in vibration characteristics of shaft.
Keywords: Cracked shaft, Crack depth, Viscous medium, Influence coefficient method.
Performance Based Optimalmachine Assignment in Reconfigurable Manufacturing
System Using Genetic Algorithm
Faisal Hasan*, P.K. Jain and Dinesh Kumar
Indian Institute of Technology Roorkee, Roorkee-247667, Uttarakhand, India
The Reconfigurable Machine Tools (RMTs) or Reconfigurable Machines (RMs) are considered to be the core
components of anyReconfigurable Manufacturing System (RMS). The presence of these RMTs or RMs on the
shop floor directly governs the reconfigurability of the manufacturing system. Reconfigurable machines have
integrable-modular structure consist of basic and auxiliary modules along with the open architecture software
to facilitate the reconfiguration process. Several potential RMTs can be assembled using these modules which
may vary in their functionalities and capacities. For any candidate operation, multiple machine configurations
may be selected. The selection of any desired machine configuration not only determines the performance of
the present system configuration but it also governs the reconfiguration of the RMT for other upcoming
operations intended to be performed in future. Thus, selecting the optimal machine configuration across
stagesof any serial production line has direct impacton theperformance and subsequent reconfiguration of the
system. In the present paper, a genetic algorithm based methodology has been proposed for optimalselection of
machine alternatives across stages of the production line. The optimal selection is based on multiple
performances parameters which includes minimizing the production cycle time and maximizing the
operational capability of the production line. The developed approach is demonstrated with the help of a
numerical illustration. For the considered numerical problem, the optimal results obtained are mc 43 , mc52 and mc12
for stages-1, 2 and 3 respectively as selected machine configuration with a fitness value of 6.8326. The other
feasible configurations so obtained are presented and are ranked on the basis of fitness values.
Keywords: Performance parameters, Optimal configuration, Evolutionary algorithm
Experimental investigation of cereal crop drying in an inclined Bubbling Fluidized Bed
1
Phyu Phyu Thant1, P.S.Robi2 and P.Mahanta3*
Indian Institute of Technology Guwahati, Guwahati, 781039
2
Indian Institute of Technology, Guwahati, 781039
*3
IIT Indian Institute of Technology, Guwahati, 781039
Experimental investigation of paddy drying by inclined bubbling fluidized bed dryer was carried out. 1 kg
batch size paddy was dried by fluidized bed with four bed inclinations viz. vertical bed (0 inclined), 15 30
and 45 for dryer air temperatures of 60°C and 65°C. The vertical and 45 inclined beds had the longest
drying time of 80 min with air temperature of 60 and 70 min for air temperature of 65 °C for the same
amount drying. While reducing the moisture content from 62% to 8.5 %, it was observed that the 30 inclined
bed had the shortest drying time of 40 and 45 min respectively with air temperatures of 65°C and 60°C to get
the above the moisture content. Moreover 15 and 30 beds saved the energy consumption due to better
hydrodynamic and heat transfer and less drying time than the two others.
Keywords: Inclined, Fluidized, Drying, Paddy
Formulating Mid-surface using Shape Transformations of Form Features
Yogesh H Kulkarni1, Anil Sahasrabudhe2 and Mukund Kale3
1
* College of Engineering Pune,
2
College of Engineering Pune
3
Siemens PLM Pune
Shapes modelled using Computer Aided Design (CAD) applications are used in downstream applications like,
manufacturing (Computer Aided Manufacturing, CAM), Analysis (Computer Aided Engineering, CAE) etc.
Use of form features is prevalent in the CAD applications, but their leveraging in the downstream applications
is not very common, especially in the CAE applications.
The initial phase of design demands for quick analysis of the model. Here, CAD models are often simplified by
removing the irrelevant features (de-featuring) and by idealizing solids to surfaces or curves(dimension
reduction), so that the CAE analysis gets performed with lesser resources and time. Mid-surface Extraction is
one of the ways of dimension reduction where thin-walled portions of a solid are idealized to surfaces lying
midway. This paper presents a novel representation scheme (called ABLE) for CAD entities and operators
including form features which is then leveraged to define the algorithm for extracting Mid-surface.
Keywords: CAD, Spatial Grammar, Form Features, Sheet Metal Features, CAE, Mid-surface
Grade Mixing Analysis in Steelmaking TundishUsing Different Turbulence Models
Md. Irfanul Haque Siddiqui1*, Pradeep Kumar Jha2
*Department of Mechanical and Industrial Engineering, Indian Institute of Technology, Roorkee, 247667
2
Department of Mechanical and Industrial Engineering, Indian Institute of Technology, Roorkee, 247667
1
Tundish plays an important role in steelmaking process. It acts as a metallurgical reactor and designed and
operated as to ensure maximum performance and quality. For advance research, physical models of tundish are
fabricated for water modeling study to validate the numerical models. Tundish modeling compromises of
complex interaction of physical, chemical and thermal interactions among steel, slag, gas and refractory. In
recent years, researchers are seen focussing on multiphase, hydrodynamic modeling of tundish system. In
present work, an assessment of RANS equations based standard k- , RNG k- , Realizable k- standard k-&,
and SST k-& turbulence models have been carried out on steelmaking tundish. A Coupled Level-Set Volume
of Fluid (CLSVOF) method was used for solving three dimensional, multi-phase numerical model. The
predictions compared against the experimental values reveal that RNG k- model gives good approximation of
F-curves and swirling of fluid at inlet-plane. Prediction made by all models except SST k-& model have shown
a satisfactory match with the experimental values.
Keywords: Tundish, Turbulence models, Steelmaking, Grade mixing, Continuous casting.
Degraded Performance Analysis of Phased Mission System
Manmohan Singh1, M.D.Jaybhaye2*, S.K.Basu3
1
VRDE, Vahan Nagar, Ahmednagar (MS) 414006
2*
Production Engineering Department, College of Engineering,Pune-41100, Email: [email protected]
3
Production Engineering Department, College of Engineering,Pune-411005, Email: [email protected]
In engineering applications many of the systems are working on the criteria of phased mission system. The
success of such system is judged on the basis of its working at each phase of system and its functioning at each
level. The total success of system depends on all success paths occurring in the system. While working with
the system reliability if the system is in continuous working condition, the components in the system may get
degraded due to wear and tear and thus causing the reduction in the successful working of the system. This
dynamic change in the failure rates of components will lead to reduction in reliability value of the system. It is
very essential to monitor the change in failure rate which lead to change in reliability and to be maintained so
as to have the required successful life span of system working. In present paper an attempt is made to analyze
the system with and without degrading factors and effect of degrading factor on reliability of system.
Keywords: Reliability, Failure rate, Degraded, Phases
Development of Low Cost Deburring Setup with Feedback Capability
S. T. Bagde1 and A. V. Kale2
Department of Mechanical Engineering, Yeshwantrao Chavan College of Engineering,
Hingna road, Nagpur, Maharashtra, India, 441110
2
Department of Mechanical Engineering, Yeshwantrao Chavan College of Engineering,
Hingna road, Nagpur, Maharashtra, India, 441110
1
To increase productivity and to improve the quality, Automation is a step beyond mechanisation. Automated
manufacturing systems includes performing operations such as processing, assembly, inspection, or material
handling and combination of more than one of these operations in the same system for reducing the number of
distinct production machines or workstations through which the part must be routed. Some of the combination
of operations performed on one system like processing and assembly, processing and material handling,
assembly and material handling, material handling and inspection is done in recent past. But very little work is
done on combination of operations such as processing and inspection on same system. This paper addresses
combination of operations like deburring and inspection on same system. A mechanism is developed in which
deburring is possible along three axes. This mechanism is also equipped with sensing devices like encoders
and load cells along with stepper motor driven axes drives. A high speed high torque motor alongwith a
grinding wheel will perform the deburring and a feedback of burr geometry will be reflected with the help of
sensing devices. Feedback in terms of variation of the speed will determine amount of burr and deflection of
tool will indicate geometry of burr. This will facilitate deburring operation alongwith quantification of the burr
geometry.
Keywords: Automated Deburring and Inspection System, Image Processing, Machine Vision
Effect of Hydraulic Accumulator on the System Parameters of an Open
LoopTransmission System
M. K. Barnwal1, N. Kumar2, Ajit Kumar3*and J. Das4
1
Indian School of Mines, Dhanbad, 826004, India,
2
Indian Schools of Mines, Dhanbad, 826004, India,
*3
Indian School of Mines, Dhanbad, 826004, India,
4
Indian Schools of Mines, Dhanbad, 826004, India,
This paper denouements the study of operating parameters of a hydraulic transmission system with and without
the application of hydraulic accumulator. In this respect, the hydraulic system, designed in the open circuit
mode, consists of the fixed displacement hydraulic pump which gives pressured fluid to the hydro-motor and
charges the accumulator as well. The load on the motor is controlled hydraulically by coupling the motor with
the loading pump, which discharges the fluid through the Pressure Relief Valve (PRV). The pressure decay of
the accumulator in the hydraulic system has been analysed and the parameters affecting the pressure decay has
been sorted out. The effect of pressure damping in the hydraulic system has also been investigated for different
sizes of accumulators under different loading conditions. The proposed hydraulic system is modelled using
MATLAB-SimHydraulics software. The study concludes with the identification of some major operating
parameters which affects the performance of the Bladder type Accumulator.
Keywords: Hydralulic accumulator, Hydraulic transmission system, Simulation
Engineering of Micro Patterned Surface Topographies – Correlating Pattern Geometry
and Bacterial Resistance
Aneissha Chebolu1, Bhakti Laha2, Monidipa Ghosh3 and Nagahanumaiah4*
1
Micro Systems Technology Laboratory, CSIR-Central Mechanical Engineering Research Institute, Durgapur,
India.
2
Dept. of Biotechnology, National Institute of Technology, Durgapur, India,
3
Dept. of Biotechnology, National Institute of Technology, Durgapur, India,
*4
Micro Systems Technology Laboratory, CSIR-Central Mechanical Engineering Research Institute, Durgapur,
India.
Bacteria resistant films and coatings being used today are highly toxic to the human body. Micro-nano patterns
created directly over solid surfaces to counter microbial activity is therefore an emerging technology in
preventing biofouling and associated problems. This paper presents investigations performed on natural
occurring and artificially machined micro-patterned surfaces, to understand the effect of such micro-nano scale
patterns on restricting bacterial activity.The effects of pattern geometry on bacterial adhesion to a surface have
been discussed using two characteristic parameters: Engineered Roughness Index and contact angle. The
bacteria cultured over these patterned surface show that the designed micro-scale geometries can effectively
reduce the growth of bacteria. The square and circular pillars with a contact angle of 125° and 119°
respectively exhibit more resistance to bacteria colonization.
Keywords: antibacterial surfaces, micro-patterning, biofouling
An Efficient Manufacturing Simulation Model for Doubly Curved Structures in
Shipbuilding
K. Thomas1, R. Sharma2* and S. K. Bhattacharyya3
1
Department of Ocean Engineering, Indian Institute of Technology Madras,
Chennai (TN) – 600 036, India
2*
Chennai (TN) – 600 036, India
3
Chennai (TN) – 600 036 India
This paper reports an efficient ‘Finite Element analysis (FEA)’ simulation model to study the line heating
process for simulating the manufacturing process of doubly curved structures. The simulation model is
implemented with commercially available software (Ansys*TM Mechanical APDL) and the source of thermal
energy is assumed to be a ‘Gaussian’ distributed heat flux. The temperature dependent material properties are
considered and the thermal history and resulting structural deformations of a standard plate due to single pass
line of heating are estimated with numerical simulation. The presented results are compared with the available
experimental results from existing literature. The deformation patterns of a plate due to line heating in different
orientations are analyzed using the simulation model and the deformation pattern is utilized to devise efficient
heating strategies.
Keywords: Thermal forming, Line heating, Transient 3D finite element analysis
Effect of the Cryogenic cooling on Surface Quality of Ground AISI 52100 Steel
P. Prudvi Reddy1, A.Ghosh2*
1
Dept. of Mechanical Engineering, Indian Institute of Technology Madras, Chennai, 600036
2*
Dept. of Mechanical Engineering, Indian Institute of Technology Madras, Chennai, 600036
Cryogenic cooling with LN2 is recognized as a green solution for effective control of machining zone
temperature, thereby resulting in substantially enhanced tool life. Although literatures mostly indicate
sustainable character of LN2 and report its positive effect as green cooling medium in machining, there are
possibilities of potential adverse effects due to extreme low temperatures. Present work makes an attempt to
explore the negative side of cryo technology in a case study, where hardened bearing steel (AISI 52100) was
ground by an alumina wheel with chilled N2 in both gas and liquid (LN2) jet form. It was observed that the
ground specimen suffered a significant dimensional deviation with the liquid jet with respect to dry and soluble
oil environment. In a similar fashion, micro hardness of work piece notably was changed and so was the
deterioration of surface finish. On the contrary, G-ratio was found to be remarkably improved, which is in line
with information in the available literatures. Extent of those adverse effects could be controlled by using
chilled N2 gas instead of LN2 jet however with a compromise on G-ratio.
Keywords: Grinding, LN2, dimensional inaccuracy, micro hardness, G-ratio.
Behavior of Thermally Sprayed Bio-ceramic Coatings after immersion in SBF: A Review
Amardeep Singh1*, Gurbhinder Singh2 and Vikas Chawla3
Punjab Technical University, Kapurthala, Punjab, India, 144601
2
Guru Teg Bahadur Khalsa Institute of Engineering & Technology, Chhapianwali-Malout, Punjab, India,
152107
3
DAV College of Engineering & Technology, Kanina, Mohindergarh, Haryana, India, 123027
*1
Significant research has been devoted to the development of hydroxyapatite (HA) as a coating material for
metallic biomaterials used in bio-implants where the biocompatibility is provided by HA while the mechanical
properties of the implant are confirmed by the metallic substrates. The in vitro tests of these coatings have
conducted by soaking in simulated body fluid (SBF) solutions to evaluate the change in morphology and
mechanical performance. The review shows that the mechanical properties like bond strength, wear resistance,
microhardness and young’ s modulus etc. of pure HA coatings found to diminish more after soaking in SBF
compared to reinforced HA coatings, but it remains constant for the heat treated coatings. The dissolution of
secondary phases in SBF is evident after immersion and the surfaces of composite coatings have completely
covered by carbonate containing apatite which shows the good bioactivity of composite HA coatings.
Keywords: Hydroxyapatite, Bioimplants, Bioceramic, SBF
A Study of Electroplating Process through Experiment and Simulation
Abhijeet Selhi1 and Sai Nikhil2
1
Mechanical Engineering, BITS, Pilani-K.K.Birla Goa Campus, 403726.
2
Mechanical Engineering, BITS,Pilani-K.K.Birla Goa Campus, 403726.
Electroplating is an economically important process, often used to reduce corrosion and improve the
appearance of objects. During electroplating a thin layer of desirable metal is deposited onto another object.
The effect of some process parameters on the weight and thickness of zinc deposited on mild steel in a typical
electroplating process is reported. This study indicates that the weight and thickness of zinc deposited on mild
steel during the process is affected by plating time, voltage distribution, distance between electrodes and their
positioning. It also validates the experimental results by simulation using COMSOL software. Simulation of
electroplating acts as a prototype for the process wherein one can predict the outcome before the actual plating.
This can help to estimate the time required for obtaining particular quantity of metal deposited (weight and
thickness) and vice versa. Results led to the conclusion that as experimental time increases the coating
thickness increases. Also, increase of distance of work-piece from center leads to decrease in coating thickness
which is evident from microscopic images of surface coatings.
Keywords: Electroplating, Simulations, Surface Coating
A Perspective Analysis on Emergence of Renewable Energy Basis Technology to
Industrial Development in Bangladesh: Prospect, Overview and Fate of the Environment.
Rakhee Mondal1*, Deeponker Sarkar2 and Debashis Saha2
1*
Department of Environmental Science and Technology, Jessore University of Science and Technology,
Jessore-7408.
2
Department of Petroleum and Mining Engineering, Jessore University of Science and Technology, Jessore7408.
The rapid increase in electricity demand for industrial growth has been threatened due to depletion of
fossilized fuel reserve. Natural gas shares a portion of 88.5% in the power supply chain which having an
amount of 15.39 TCF reserve available that would be enable enough to serve the national grid for power
generation up to 2030 unless further discovery. The coal reserve of about 1222 million ton may not be of use
due to unavailability of extraction via selective method as well as importation of low rank coal would not be
economic viable enough for the sustainable industrial infrastructure due to toxic gas emission. Considering the
geographical status Bangladesh is located in a position where the potential sources of renewable energy
including solar, wind, biomass, hydro, tidal, and geothermal energy are quite reliable as well as affordable.
Deficiency in power sector may be lessened through the implementation of renewable energy technologies in
addition to the conventional sources of fossils fuel. Results shown that, an amount of approximate 55899 MW
power may be accumulated to the supply chain for power generation in an effective sustainable and reasonable
manner. The following research paper is based on renewable energy technology along with all probable
sources from perspective of Bangladesh. This paper provides a comprehensive study from field data and open
literature available regarding significant implication for a decision making in an effort to enhance energy
production via using green and sustainable energy technology.
Keywords: Industrial Growth, Power Supply, Renewable Energy, Sustainable Technology.
Porosity Reduction in Laser Sintered Specimen Made of Tungsten Carbide and Cobalt
Powder
Subrata Kumar Ghosh1*, Alok Kumar Das2, Sojiram Meena3andPartha Saha3
Department of Mechanical Engineering, National Institute of Technology Agartala,
Tripura-799055,
2
Department of Mechanical Engineering, Indian School of Mines Dhanbad, Jharkhand- 826004,
1*
3
Department of Mechanical Engineering, Indian Institute of Technology Kharagpur, Kharagpur-721302
In the present investigation, the selective laser sintering process was applied to prepare WC-Co composite
material. The pulsed Nd: YAG laser was used for the process. The optimum level of parameters such as
composition of powder, layer thickness, hatching distance, pulse energy, pulse width and distance from focal
plane were obtained using Taguchi method for lower porosity. The 80 wt. % of WC and 20 wt. % of Co
powder mixture, layer thickness of 300 µm, the pulse width of 14ms, pulse energy of 19 J, hatching distance of
400 µm and layer distance of 450 µm below focal plane are offering the lower porosity within the range of
study. The optical micrograph showed the interconnected pores on the top surface of the specimen. The
scanning electron microscopy (SEM) showed the distribution of WC particle. The composition and hatching
distance and layer thickness are the significant parameters. The increase in amount of Co and lower hatching
distance reduce the porosity of the specimen.
Keywords: Selective laser sintering, Taguchi method, SEM, XRD
Investigation of Different Combustion Chamber Geometry of Diesel Engine Using CFD
Modelling of In-Cylinder Flow for Improving the Performance of Engine.
A.M. Indrodia1, N.J. Chotai2 and B.M.Ramani3
Department of Mechanical Engg. Faculty of PG Studies & Research, MEFGI Rajkot 360003
2
Department of Mechanical Engg. Faculty of PG Studies &
Research, MEFGI Rajkot 360003
3
Department of Mechanical Engg Faculty of PG Studies & Research, MEFGI Rajkot 360003
1
The present research investigates the effect of combustion chamber geometry. The MINI-PETER Diesel
Engine generally used in Agricultural field is investigated in present work. Baseline geometry and modified
geometries of specified engine is analyzed using CFD simulation tool of CAE. The result of the baseline
geometry and modified geometries are compared and presented in the form of emission parameters like.
NOx, CO2, CO, HC. From the result it is concluded that the swirling and turbulence kinetic energy is higher
in modified geometries compared to baseline geometry which result in higher efficiency of the engine.
Keywords: Combustion Chamber, Piston Geometry, CFD, Swirl, Diesel Engine Emission, NOx.
Prediction of Remaining Useful Life of an Aircraft Engine under Unknown Initial Wear
Amit Kumar Jain1*, Pradeep Kundu2and Bhupesh Kumar Lad3
*Discipline of Mechanical Engineering, Indian Institute of Technology Indore,
M.P., India, 453441.
2
Discipline of Mechanical Engineering, Indian Institute of Technology Indore, M.P. ,
India, 453441.
3
Discipline of Mechanical Engineering, Indian Institute of Technology Indore, M.P. ,
India, 453441.
1
Effectiveness of Condition Based Maintenance (CBM) strategy depends on accuracy in prediction of
Remaining Useful Life (RUL). Data driven prognosis approaches are generally used to estimate the RUL of
the system. Presence of noise in the system monitored data may affect the accuracy of prediction. One of the
sources of data noise is the presence of unknown initial wear in the samples. Present paper illustrates the effect
of such initial wear on prediction accuracy and presents the guidelines to handle such initial wears. Two
Artificial Neural Network (ANN) models are developed. First model is developed with the help of complete
data; while the second model is developed after removing samples with abnormal initial wear. and R control
chart is used to screen the samples with abnormal initial wear. It is found that the presence of initial wear
significantly affects the prediction accuracy. Also, it is found that RUL estimation for a unit with short history
tends to produce great uncertainty. Hence, it is recommended that RUL prediction should be continuously
updated with age of the unit to increase the effectiveness of CBM policy.
Keywords: Prognosis, Remaining Useful Life, Artificial Neural Network, Control Chart.
Vibration Analysis of Variable Compression Ratio Engine Using Virtual Instrumentation
Abhishek singh1, H. Chelladurai2*and Akhilesh kumar chaudhary3
1,2,3
Department of Mechanical Engineering, PDPM Indian Institute of design and manufacturing, Jabalpur,
MP, 482005.
Email: [email protected].
Diesel engines have various vibration sources, such as fuel combustion pressure, fuel injection, reciprocating
and rotating motions, valve operation, and gas flows. Many literature works are available in IC engine
vibration measurement system. The uses of virtual instrumentation in vibration analysis are very scanty. The
objective of the present work is to analyze the engine block vibration, performance and emission behavior of
variable compression ratio diesel engine using virtual instrumentation. The main objective of this paper is to
develop a low cost and effective IC engine block vibration measurement system using virtual instrumentation
system. A systematically designed experiment using the central composite face centered design (CCFD) has
been performed and parametric analysis of variable compression ratio engine (VCR) has been carried out to
relate input and output parameters. The regression model has been developed to study the emission behavior of
diesel engine at various operating conditions. From this study, it is observed that using a MEMS accelerometer
sensor, the low cost virtual instrumentation vibration analysis system can be developed and results show that
the increased fuel injection pressure increases the block vibration of engine and increase in compression ratio
reduces block vibration,HC and CO emission but increases NO emission.
Keywords:VCR engine, Virtual instrumentation, Data acquisition, Vibration signal.
Condition monitoring of rotating shaft using virtual instrumentation
Ajay Chaubey1, H.Chelladurai2*and Subir Singh Lamba3
PDPM Indian Institute of Information Technology, Design and Manufacturing,Jabalpur,India,
1
Email: [email protected], *2Email: [email protected], 3Email: [email protected]
1,2*,3
Shaft is a component which is subjected to various forces when it is used in the processes and utility plants like
high speed compressors, steam and gas turbine, generators and pumps etc. Therefore, safety, reliability,
efficiency and performance of shafts become a major concern for better performance of such equipments. To
control the vibration effects during working condition, various parameters such as speed, diameter and bend
values have been investigated in the present work and a regression model has been developed to relate the
input and output parameters to minimize the vibrationlevels. Error analysis has been carried out between
regression model and experimental values to know the feasibility of the model. Two methods, namely,
Response Surface Methodology (RSM) and Artificial Neural Network (ANN) were used to predict the
responses of the rotating shaft. The investigations were focused around three parameters, three levels and
central composite face centered design outlined with full replication procedure and regression model was
created. ANN is used to predict bend values of the rotating shaft. To acquire lateral vibration (waveform)
signal, a virtual instrument simulation test system has been developed using Lab VIEW. In this study, an
attempt has been made to estimate the bend levels using Multi-Layer Perceptrons (MLP) architecture. The feed
forward back propagation algorithm is chosen for training and testing the experimental data.
Keywords:Vibration, Signal Analysis Technique, Data Acquisition, Artificial Neural Network
Mathematical Modeling of Wave Propagation in Elastic Solids
1
P. Srinivasa Rao1*and Perumalla Janaki Ramulu1
The deformation in solids results in pressure wave propagation which is a challenging problem from material
scientist point of view. When a heterogeneous medium homogenized an anisotropic expansion takes place
introducing non linear effects which makes the problem more complex to handle. These expansion waves are
to be suppressed to nullify the anisotropic effects. Generally the finite deformation approach is used to study
such wave propagation which fails to tackle the nonlinearity of the large deformation and the geometric
nonlinearity in elastic solids. Nevertheless the mathematical modeling of such wave propagation problems in
elastic solids has always been interesting. In the present paper wave propagation in an elastic medium has been
considered to mathematically study and model the nonlinear wave propagation in elastic solids.
Keywords: Elastodynamics, Nonlinear waves, Deformation in elastic solids
Designand Developmentof Manually Operated Seed Planter Machine
1*
Kyada, A. R1*and Patel, D. B.2
LDRP Institute of Technology and Research, Gandhinagar, 382481,
2
Gandhinagar Institute of Technology, Gandhinagar, 382721,
The basic requirements for small scale cropping machines are, they should be suitable for small farms, simple
in design and technology and versatile for use in different farm operations. A manually operated template row
planter was designed and developed to improve planting efficiency and reduce drudgery involved in manual
planting method. Seed planting is also possible for different size of seed at variable depth and space between
two seed. Also it increased seed planting, seed/fertilizer placement accuracies and it was made of durable and
cheap material affordable for the small scale peasant farmers. The operating, adjusting and maintaining
principles were made simple for effective handling by unskilled operators (farmers).
Keyword: Seed, Sawing, Planting.
Simple Fabrication of PDMS Based Microfluidic System for Mixing And Detection
System
Khalid Anwar1*, Sandip S Deshmukh1and Sun Min Kim2
Department of Mechanical Engineering, BITS-Pilani, Hyderabad Campus, Hyderabad, 500078, Email*:
[email protected]
2
Department of Mechanical Engineering, Inha University, Republic of Korea
1*
Simple fabrication and integration of consecutive analysis system is a key feature for lab-on-a-chip (LOC)
device. Soft-lithography method is used to fabricate a poly-dimethylsiloxane (PDMS) based microfluidic
system which is faster and less expensive than other conventional methods such as etching glass and silicon.
Nanogap was generated between two microchannels simply by the breakdown of PDMS layer using electric
shock, without using any state-of-art method. The device consists of two parts: Micro-mixer and
Preconcentration for detection system. The Micro-mixer is passive and planer, which is easy to fabricate, is
used for mixing the protein with their fluorescent conjugate. Consecutively, Preconcentration of protein is
done based on electrokinetic trapping trapping of protein near the nanogap. This device can be used to bring
the concentration within the detection limit, because the sensitivity of detection system is still restricted to
detect target analyte with low concentration in microfluidic system.
Keywords: Micro-Nanofluidic System, Micromixer, Protein Preconcentration, Electrokinetic Trapping
Automatic Feature Recognition of Cylinder And Knukcle Thread from Neutral Files
M.M.M.Sarcar1, P.Madar Valli2 and V.Naga Malleswari 3*
Department of Mechanical Engineering, GIET, Odisha- 765022, India,
2
Department of Industrial Engineering, GITAM University, Visakhapatnam-530045, India,
3*
Department of Industrial Engineering, GITAM University, Visakhapatnam-530045, India,
1
The computerization of the design and manufacturing in the mechanical industry results in the Computer
Aided Design (CAD) and Computer Aided Manufacturing (CAM). One of the main integration efforts of the
recent computer integrated manufacturing (CIM) research has been the integration of CAD and CAM through
computer aided process planning (CAPP). Automatic feature recognition is the main input for CAPP. This
paper presents STEP AP203 based feature recognition methodology to identify the manufacturing features.
Methodology utilizes the neutral file which contains the information about the faces, edge curves, surfaces,
edge loops, vertices, coordinate points, location planes and location axes of the features. A rule based search is
employed to recognize manufacturing features and to interpret the characteristic attributes of dimension sets
that denote length and radius dimensions, type of feature (cylinder, thread) of the designed part is extracted.
The proposed methodology is developed for 3D rotational parts that are created by using solid modeling
software, CATIA. A generalized Java code has been written to extract the data from STEP file and to
recognize the features. The proposed software is implemented and tested for many complex 3D models.
Keywords: STEP file; Feature recognition; Thread; Rotational parts
Optimizing Preload and Coefficient of Friction for Surface Acoustic Wave Linear Motor
Basudeba Behera1*and Harshal B. Nemade2
1*,2
Department of Electronics and Electrical Engineering,
Indian Institute of Technology Guwahati, India, Pincode: 781039
The physical parameters influencing to the motion of surface acoustic wave (SAW) linear motor was
investigated here in this work.The driving of SAW motor is developed utilizing the frictionforce phenomena.
Slider travels in reverse direction of propagation of the wave due to friction where,itis placed on the Rayleigh
waves generated on a stator. A 128°rotated Y cut X propagated LiNbO3 piezoelectric substrate is used as stator
where comb structured Aluminum (Al) electrodes was fabricated at the both end of it. Burst of signals applied
to the motor arrangement for making it into motion and study the characteristics. The frequency applied for the
motion is 8.82 MHz which is optimized and generated from different RF power range. In this study initially we
optimized the required preload need to apply to the slider for the movement. After that the coefficient of
friction to drive the slider on the friction surface of the stator is calculated. Observed the time which is taken
by the slider to achieve it’ s the steady state. The displacement of the slider with a greater velocity of 0.3 m/s
was achieved with a preload of 5mN.
keywords: SAW, Rayleigh wave, USM
Parametric Studies on Side Impact Beam Tube
Rajesh Male1, Ashwin Karthikeyan2* and Krishna Srinivas3
Corporate TechnologyCenter, Tube Investments of India Ltd, Chennai-600054,
1
2*
2
Passenger cars endure side impact collisions which can quite prove fatal from the point of the availability of
lesser crumple zone. Side impact beam (SIB) is equipped in passenger cars and other ground vehicles as a
safety structural member. SIB strengthens the doors of the vehicles and lowers the risk factor in side collisions.
This paper presents the parametric studies carried out on the side impact beam (SIB) tube. Material, outer
diameter and thickness of the tube are the main parameters which can change the load carrying capacity and
energy absorption characteristics of an SIB tube. In this regard, to improve the load carrying capacity and
energy absorption characteristics it is beneficial to study the effect of each parameter on SIB tube. The proper
combination of these parameters may improve the overall structural behavior of the tube. A Finite Element
(FE) model using LS-Dyna has been developed for carrying out the parametric studies.
Keywords: Intrusion, SIB, Energy absorption
Analysis of Optimal Methodology for Geometry Reconstruction of an Airborne Launcher
Kushal Singh1*, L Siva Rama Krishna2, B. Hari Prasad3 and P. Bhattacharjee4
1*
Defence Research & Development Laboratory, Hyderabad, 500058,
2
Dept. of Mechanical Engineering,UCEOU, Hyderabad, 500007,
3
4
An Airborne Launcher consists of subassemblies and components made of either regular, freeform or the
combinations of both types of geometrical features. Geometry reconstruction of Launcher is required to study
the feasibility of Launcher with Aircraft and missile and for the interface study of Launcher with Pylon. The
optimal method provides minimum error in geometry reconstruction and preserves the design intend. In the
present work various geometry reconstruction methods like Conventional measuring instruments, Coordinate
Measuring Machine (CMM) and Laser scanner are considered. The effect of different methods adopted for
capturing geometrical information and process of geometry reconstruction are analyzed.
Keywords: Geometry Reconstruction, CMM, Laser Scanning, CAD modeling
Analysis of the Novel Brake Rotor Using FEM
A. K. Matta1 and V. Purushottam2
Dept. of MECH,GMRIT,Rajam,Srikakulam Dst,A.P-532127,India.
2
Dept. of MECH,GMRIT,Rajam,Srikakulam Dst,A.P-532127,India.
1
The first experimental setup premeditated to study the effect of thermal stresses on the brake rotor. In the main
equipment, a motor, non-contact infrared thermometer, brake pads and design of internally ventilated cross
drilled disc are described. The finite element method (FEM) is adopted to analyze the thermal stresses and
static strength of the brake rotor.It is demonstrated that the static strength and thermal stresses are competent.
For the 120 mm outer diameter and 80mm inner diameter disc, three design schemes are put forward. After
comparing, the internally ventilated cross drilled disc is selected.The FEM is pragmatic to crisscross thermal
stresses, static strength as well as distortions. The results show that the disc’ s distortion is mainly due to the
temperature of the disc which leads to its inefficient braking. The calculated deformation is less than
0.0005mm, and maximum temperature is 82.94 °C despite of actual experimental measurements 0.0 mm and
temperature 82.6 °C. The internally ventilated cross drilled disc completely placates the design requirements.
Keywords: Brake rotor, Design, Finite element method

souvenir - IIT Guwahati

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